EPS Power Pack Connector Plate With Metal Ring Press Fit

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Solution Overview

Problem

The existing electric power steering (EPS) systems face complexity in assembly and shipping due to the use of metal connector plates, which require multiple nuts and studs for coupling, increasing manufacturing and assembly processes while providing advantages in grounding, conductivity, and heat transfer.

Innovation Solution

A manual power pack assembly for EPS systems using a plastic connector plate with a metal ring for press fit coupling, reducing the need for metal fasteners and simplifying the assembly process, and incorporating metal pins for grounding and heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal connector plate is used, then grounding, conductivity, and heat transfer are improved, but device complexity and assembly difficulty increase due to multiple nuts and studs

Engineering Contradiction:
Improvegrounding and conductivityVSAvoidassembly complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The connector plate uses a composite structure combining plastic and metal components. The plastic body provides structural support and insulation, while integrated metal features (such as metal inserts or coated surfaces) provide grounding and conductivity pathways. This composite approach maintains electrical reliability while eliminating the need for separate metal fasteners and reducing assembly complexity.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The invention merges multiple functions into the connector plate itself. The plate integrates structural support, electrical grounding, thermal conduction, and mechanical fastening capabilities into a single component. By combining these functions, the design eliminates the need for separate studs and nuts, reducing the number of parts and simplifying assembly while maintaining grounding and heat transfer through the integrated metal features.

Inventive Principle:
Principle #5Merging (Combining)

2Strength

If a metal connector plate with multiple fasteners is used, then structural strength is improved, but ease of manufacture and shipping are worsened due to increased part count

Engineering Contradiction:
Improvestructural strengthVSAvoidmanufacturing and shipping ease
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The connector plate combines multiple components into a single integrated part. The structural strength previously provided by metal studs and nuts is now incorporated into the plate itself through integrated metal fastening features or reinforced结构设计. This reduction in part count simplifies manufacturing processes, reduces assembly steps, and decreases shipping volume and complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The use of composite materials (plastic with metal reinforcements or inserts) allows the connector plate to achieve structural strength comparable to all-metal designs. The metal inserts or coated regions provide the necessary mechanical strength for fastening, while the plastic matrix provides structural support and insulation. This composite approach maintains strength requirements while simplifying the overall assembly and reducing part count.

Inventive Principle:
Principle #40Composite materials

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 solution reduces the number of metal mechanical fasteners required, simplifying manufacturing, shipping, and assembly while maintaining essential functions like grounding and heat transfer, thereby enhancing the efficiency and ease of handling in EPS systems.

Implementation Method 1

a metal ring disposed on an inner diameter of the cylinder and in contact with the outer diameter of the motor housing

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The metal provides certain advantages and assists with grounding, conductivity, and heat transfer

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11866104B2Power pack for electric power steering system
Publication Date: 2024.01.09 STEERING SOLUTIONS IP HOLDING CORP
  • US11866104B2 patent drawing
  • US11866104B2 patent drawing
  • US11866104B2 patent drawing

AI summary

A manual power pack assembly for an electric power steering (EPS) system includes a motor housing at least partially enclosing a motor and having an outer diameter. The manual power pack assembly also includes a connector plate formed of a material comprising plastic, the connector plate having a first side, a second side, and a cylinder extending from the first side. The manual power pack further includes a metal ring disposed on an inner diameter of the cylinder and in contact with the outer diameter of the motor housing.