Housing Muffler Embedded Electromechanical Component
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Solution Overview
Problem
Existing housing shells with electromechanical assemblies for vehicle brake systems have complex designs with multiple parts, making them difficult to produce and assemble, and often require additional sealing components like O-rings for connector plugs, which complicates the installation process and increases space usage.
Innovation Solution
A housing shell design with a modular, one-piece fixing body that encloses electrical conductors and is integrated into the injection molding process, eliminating the need for separate O-rings and additional connector plugs, and featuring a dimensionally stable fixing body that simplifies production and reduces part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate connector plugs with O-rings are used to seal electrical conductors, then sealing function is achieved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent integrates the connector plug housing directly into the housing shell as an integral component, eliminating the need for separate connector plugs and O-rings. The housing shell itself forms the sealing structure, combining what were previously separate components into a unified design that reduces part count while maintaining sealing functionality.
2Reliability
If traditional separate connector plugs are used, then electrical conductor sealing is achieved, but production time increases due to multiple assembly steps
Solution Approach 1:
The connector plug housing is formed as an integral part of the housing shell through injection molding, allowing both components to be manufactured in a single process step. This eliminates the need for separate assembly operations and reduces production time while ensuring consistent sealing quality.
Solution Approach 2:
The housing shell is designed with pre-formed sealing surfaces and integrated connector plug structures during the injection molding process. This preliminary formation of sealing features eliminates the need for subsequent sealing operations or manual assembly steps, streamlining production.
3Ease of operation
If flexible sheathed wires are used independently for electrical conductors, then installation flexibility is improved, but space requirements increase
Solution Approach 1:
The electrical conductors are routed through integrated channels and pathways formed within the housing shell structure itself. This nesting of conductors within the housing geometry allows flexible wire installation while minimizing the overall space required, as the conductors follow compact routes through the housing rather than requiring separate conduit space.
Data Source
Figure 1~5
AI summary
The muffler has an embedded component (2) with an electromechanical or electronic component, and a connecting plug fixed with an external connection, and enclosing a free contact end (14) of an electrical conductor (16). The conductor is aligned outwards from the component (2) to the connecting plug by a side wall. The conductor is surrounded by a plastic material of a fixing body (19) in an area that runs from the electronic component up to the contact end, where the fixing body is fixedly embedded by the muffler in a form-fit manner.