Electric Machine Housing Cover with Embedded Circuit
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Solution Overview
Problem
Existing housing covers for electrical machines in vehicle electronics are poorly protected against mechanical and environmental influences, and require complex cable connections and shielding to meet electromagnetic compatibility standards, which are costly and prone to exposure.
Innovation Solution
A housing cover with a thermoplastic outer shell and a duroplastic inner core that embeds the electrical circuit arrangement, providing mechanical and moisture resistance, and eliminating the need for external cables by forming a direct connection through a bearing seat and mounting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If devices with circuit electronics are connected to electrical machines via cables, then electrical connection is achieved, but the assembly is poorly protected against mechanical environmental influences and aging
Solution Approach 1:
The patent merges the cable connection arrangement with the housing structure by integrating the electrical connection directly into the housing cover. The circuit electronics are embedded in the housing cover, eliminating the need for separate cables and their associated sealing requirements. This integration provides better protection against mechanical environmental influences while reducing overall device complexity.
Solution Approach 2:
The housing cover acts as an intermediary structure that combines both mechanical protection and electrical connection functions. By embedding the circuit electronics and electrical connection elements directly in the housing cover, it mediates between the internal electronics and external connections, providing sealed protection while enabling electrical connectivity without traditional cables.
2Reliability
If devices with circuit electronics are connected via cables, then electrical connection is achieved, but elaborate shielding measures are required to meet electromagnetic compatibility requirements
Solution Approach 1:
The patent combines the electrical connection function with the housing structure itself. The circuit electronics are embedded directly in the housing cover, and electrical connections are made through integrated connection elements rather than external cables. This integration eliminates the need for elaborate shielding measures, achieving electromagnetic compatibility while reducing device complexity.
3Reliability
If a conductor carrier with oil-resistant sealing ring is used, then sealing against the housing wall is achieved, but the conductor carrier requires an interface for receiving the sealing ring and is not fully encapsulated
Solution Approach 1:
The patent merges the sealing function with the housing cover structure by embedding the circuit electronics directly in the housing cover. This integration eliminates the need for separate conductor carriers and oil-resistant sealing rings, providing full encapsulation of the electronics while reducing the complexity of the sealing arrangement.
Solution Approach 2:
The housing cover serves as an intermediary that provides both structural support and sealing protection. By embedding the circuit electronics and providing integrated electrical connection elements, the housing cover mediates between the internal electronics and external environment, achieving full encapsulation without requiring separate sealing components.
4Reliability
If multiple seals are integrated into the housing cover and housing shell, then sealing protection is achieved, but the sealing arrangement becomes complex with several parts
Solution Approach 1:
The patent merges all sealing functions into the housing cover structure itself by embedding the circuit electronics directly in the housing cover. This integration eliminates the need for multiple separate seals in the housing cover and housing shell, providing comprehensive sealing protection while reducing the number of sealing parts and overall arrangement complexity.
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 offers enhanced protection against environmental influences, improved heat dissipation, and eliminates the need for complex shielding and cables, resulting in a cost-effective and reliable connection for electrical machines.
Implementation Method 1
The thermoplastic outer shell offers the advantage of high resistance to mechanical stress as well as to the effects of moisture, water and aggressive substances.
Implementation Method 2
The inner core made of thermoset material ensures advantageous heat dissipation due to the easily adjustable thermal conductivity of the thermoset.
Implementation Method 3
The inner core made of thermoset material ensures advantageous heat dissipation due to the easily adjustable thermal conductivity of the thermoset.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a housing cover (1) for an electric machine comprising a housing (11). According to the invention, in order to achieve advantageous construction conditions, the housing cover (1) comprises an outer casing (2) made of a thermoplastic material, an inner core (3) made of a thermoplastic material is provided, an electric circuit assembly (4) is embedded in the inner core (3), which can be connected via an electrical connection element (6), and the housing cover (1) is shaped in such a way that an end-side opening of the housing (11) of the electric machine can be closed in a sealing manner with same.