Automotive Housing Membrane Prestressing via Star-Shaped Ribs
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Solution Overview
Problem
Existing housing units for electrical components in motor vehicle water circulation pumps are prone to moisture exposure during the joining process, are costly, and overly complex in manufacturing, due to issues with membrane detachment and inadequate pressure equalization.
Innovation Solution
A housing unit design featuring a funnel-shaped recess with a star-shaped rib arrangement to prestress the membrane, a cover closing element with a smaller diameter and material connections via support elements, and centering elements for secure installation, ensuring a sealed and ventilated environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a membrane is used to protect electrical components from moisture, then protection against moisture is improved, but the membrane becomes detached during joining process exposing components to moisture again
Solution Approach 1:
The membrane is prestressed before the joining process by the rib arrangement, which prevents flapping or beating during ultrasonic welding. This preliminary action ensures the membrane remains securely attached throughout the manufacturing process, maintaining its moisture protection function.
Solution Approach 2:
The rib arrangement creates localized prestressing at specific points on the membrane, concentrating the stabilizing effect where needed during the joining process. This local quality enhancement prevents detachment without requiring overall membrane reinforcement.
2Adaptability or versatility
If a ventilation hole is provided in the cover for pressure equalization, then response to temperature changes and external pressure is improved, but moisture or water vapor cannot be effectively removed
Solution Approach 1:
The cover closing element is designed with a porous or permeable structure that allows water vapor to pass through while maintaining pressure equalization. This enables both functions simultaneously: adapting to pressure changes and removing harmful moisture through the same component.
Solution Approach 2:
The cover closing element serves multiple functions: it provides pressure equalization through ventilation openings and simultaneously enables moisture removal through its design. This multi-functionality resolves the contradiction by making a single component address both needs.
3Reliability
If a complex cover structure with membrane and ventilation is used, then protection and pressure equalization are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The cover closing element combines multiple functions (ventilation, moisture removal, and structural support) into a single integrated component. This merging reduces the number of separate parts and simplifies manufacturing while maintaining the required protection and pressure equalization functions.
Solution Approach 2:
The basic cover element is designed to perform multiple functions simultaneously: sealing, venting, and supporting the membrane. This multi-functionality reduces overall device complexity by eliminating the need for separate components for each function.
4Area of stationary object
If the cover closing element has the same diameter as the recess, then complete coverage is improved, but ventilation openings are not automatically formed
Solution Approach 1:
The cover closing element is designed with an asymmetric size relationship to the recess, having a smaller diameter that intentionally creates peripheral gaps. This asymmetric design automatically forms ventilation openings during assembly without requiring additional manufacturing steps.
Solution Approach 2:
The size difference between the cover closing element and the recess automatically creates ventilation openings during the assembly process itself, without requiring separate venting operations. The structure serves its own ventilation function through its geometric design.
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
Prevents membrane detachment during assembly, ensures a sealed and ventilated environment for electrical components, allowing for pressure equalization and effective moisture removal, while simplifying and securing the installation process.
Implementation Method 1
the opening (26) having a rib arrangement (28) that pretensions the membrane (34)
Implementation Method 2
the recess (24) being funnel-shaped so that water in the recess (24) can flow off in any installation position
Implementation Method 3
the joining process, for example by ultrasonic welding of the cover closing element or the housing cover arrangement
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a housing unit for electrical components for use in the automobile sector, comprising a housing part which can be closed in a sealed manner by a housing cover arrangement, wherein the housing cover arrangement has a membrane and at least one ventilation opening, wherein the housing cover arrangement (20) has a main cover element (22) having a recess (24), wherein an opening (26) is provided in the recess (24), which can be closed in a sealed manner by the membrane (34), wherein the opening (26) has a rib arrangement which pretensions the membrane (34) and wherein a cover closure element (38) is provided which closes the recess (24) with at least one ventilation opening.