EV Power Converter Housing With Elastic Layer for Vibration Damping
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Solution Overview
Problem
Power conversion electronic appliances in electric and hybrid vehicles experience mechanical stresses due to vibrations, leading to premature wear and increased production costs.
Innovation Solution
Incorporating an elastically deformable layer made of materials like sponge, which is electrically insulating and can be thermally conductive, positioned between electrical components and the cover of the appliance to dampen vibrations and dissipate heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glue drops are applied between electrical components to dampen vibrations, then the structural integrity and operating life of components are preserved, but the production time increases and production volumes are negatively affected
Solution Approach 1:
The patent combines multiple electrical components (capacitors, inductors, resistors, semiconductors) into a single integrated power conversion module housing. This consolidation eliminates the need to apply individual glue drops between numerous separate components, thereby maintaining vibration protection while significantly reducing assembly time and increasing production efficiency.
Solution Approach 2:
The integrated module serves multiple functions simultaneously: it provides mechanical support, vibration damping, electrical insulation, and structural containment for all power conversion components. This multi-functional design replaces the need for multiple separate protective measures (including individual glue applications) that were previously required for each component.
2Duration of action of stationary object
If glue is applied between electrical components to reduce vibration stresses, then component durability is improved, but the amount of glue required and working time increase, leading to higher production costs
Solution Approach 1:
By merging all power conversion components into a single integrated module, the patent eliminates the need for repetitive glue application operations between numerous individual components. The module is manufactured as a unified structure with internal vibration damping features, drastically reducing assembly time and labor costs while maintaining component protection.
3Object-affected harmful factors
If numerous glue drops are applied between electrical components to dampen vibrations, then vibration protection is achieved, but the complexity of the manufacturing process increases and production efficiency decreases
Solution Approach 1:
The patent integrates all power conversion components into a single modular assembly with built-in vibration damping structures. This eliminates the complex, multi-step process of individually positioning and applying glue drops between numerous components, thereby simplifying the manufacturing process while maintaining effective vibration protection.
Solution Approach 2:
The integrated module housing acts as an intermediary structure that provides centralized vibration damping and mechanical support for all internal components. This single intermediary structure replaces the need for multiple localized glue applications, simplifying the manufacturing process while effectively isolating components from vibration.
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 elastically deformable layer effectively reduces mechanical stresses on electrical components, increases their operational life, and lowers production costs by simplifying the manufacturing process and reducing material usage.
Implementation Method 1
at least one layer (6) which is arranged in contact with each of the electrical components (4) and is adapted to dampen the vibrations transmitted by the electrical vehicle to the electrical components (4)
Implementation Method 2
the layer (6) is made at least partly of an elastically deformable material
Implementation Method 3
the layer (6) is made at least partly of at least one thermally conductive material
Data Source
AI summary
The power conversion electronic appliance (1) for electric or hybrid vehicles, installable within at least one electric or hybrid vehicle and connectable to at least one battery of said vehicle, comprises: an external container (2); an electronic circuit (3) housed in said container (2) which is connectable to the battery and comprises a plurality of electrical components (4) configured for the conversion of an input current/voltage into a predefined output current/voltage to be sent to the battery; and at least one cover (5) intended to close the container (2) at the top; at least one layer (6), positioned between the electrical components (4) and the cover (5) and made of an elastically deformable material which is arranged in contact with each of the electrical components (4) and is adapted to damp the vibrations transmitted by the electrical vehicle to the electrical components (4).