E-Axle Cooling Circuit Seal with Overflow Leak Diversion
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Solution Overview
Problem
Existing electric axis modules face challenges in effectively sealing the cooling circuit, which can lead to coolant leakage into the power electronics cavity, potentially damaging semiconductor components.
Innovation Solution
A compact sealing arrangement is proposed, featuring a pipe-shaped component with two sealing elements, one of which includes an overflow opening in the housing wall, ensuring reliable sealing and preventing coolant ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing arrangement with multiple sealing elements is used in the cooling circuit, then the sealing reliability is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealing arrangement. The tubular insert incorporates both a first sealing element (O-ring) in a circumferential groove and a second sealing element (bead) on the end face, merging what would traditionally be separate sealing components into one unified structure that prevents coolant leakage at multiple locations simultaneously.
Solution Approach 2:
The sealing arrangement is segmented into distinct functional zones: the first sealing element addresses sealing at the circumferential interface between the tubular insert and housing, while the second sealing element handles the end face interface. This segmentation allows each sealing element to be optimized for its specific sealing location and pressure conditions.
2Reliability
If an overflow opening is provided between sealing elements, then the protection against coolant leakage is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The overflow opening is pre-positioned in the housing at a specific location between the two sealing elements. This preliminary placement ensures that if the first sealing element fails, coolant can immediately escape through the pre-positioned overflow opening before reaching the power electronics, providing a fail-safe mechanism without requiring complex real-time monitoring or adjustment systems.
3Reliability
If the tubular insert is received in a recess of the housing, then the sealing effectiveness is improved, but the assembly difficulty increases
Solution Approach 1:
The second sealing element features a spherically curved sealing surface with a specific spherical radius. This curvature allows the bead to conform to the recess geometry and maintain uniform contact pressure across the sealing interface, improving sealing effectiveness while the spherical geometry facilitates smooth insertion and self-alignment during assembly, reducing assembly difficulty.
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
The solution provides a reliable two-way seal, ensuring the power electronics remain dry and functional, while simplifying assembly and reducing production costs by minimizing the number of components and potential damage during installation.
Implementation Method 1
a sealing arrangement (40) for a cooling circuit... comprising a tubular insert (48) on which a first sealing element (62) is arranged, wherein a second sealing element (64) is assigned to one of the end faces of the tubular insert (48)
Implementation Method 2
an overflow opening (56) is provided between the sealing elements (62, 64), wherein the tubular insert (48) is received in a recess (52) of a housing wall (22) and the overflow opening (56) is designed in the wall of the recess (52) of the housing (12)
Data Source
Figure 1
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AI summary
The invention relates to a seal arrangement (40) in the cooling circuit of an E-axle module (10) comprising at least one electric machine (14) and at least one power electronics system (24). The seal arrangement (40) comprises a tubular insert (48) on which a first sealing element (62, 72) is arranged and which has an associated further sealing element (64, 76, 80) on one of its end sides (96, 98). An overflow opening (56) is located between the sealing elements (62, 72, 64, 76, 80). The invention also relates to the use of the seal arrangement (40) in the cooling circuit between an electric machine (14) and a power electronics system (24) of an E-axle module (10) of an electrically driven vehicle.