Integrated Electrical Housing for 48V-12V Converters and Control Units
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Solution Overview
Problem
Integrating a 48-volt battery and associated components into a pre-existing vehicle structure presents spatial and routing challenges due to limited space and the need for new hoses and cables.
Innovation Solution
A housing for electrical components that supports multiple components, including a 48V-12V power converter, engine control unit, heating grid control unit, and 12V battery safety module, with features for compact installation and optimal connection, allowing these components to be arranged parallel or at an acute angle, and includes elements for attachment to a mounting structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate housings are used for each electrical component, then each component can be individually protected and installed, but the overall device complexity increases and installation space is not optimized
Solution Approach 1:
The patent combines multiple separate housings into a single integrated housing structure that accommodates multiple electrical components (48V-12V voltage converters, engine control unit, heater control unit, battery safety module, and terminal blocks) within one unified enclosure. This merging approach maintains individual component protection while reducing overall structural complexity and optimizing space utilization in the vehicle engine compartment.
2Reliability
If multiple separate housings are installed in the vehicle, then each component has dedicated mounting, but the installation time and assembly complexity increase
Solution Approach 1:
The integrated housing design allows multiple electrical components to be mounted simultaneously within a single housing unit, reducing the number of separate installation operations required. The housing includes multiple fixing elements and mounting structures that accommodate different component types in a unified assembly process, thereby reducing installation time while ensuring reliable mounting for all components.
Solution Approach 2:
The housing structure is designed with universal mounting capabilities that can accommodate various types of electrical components (voltage converters, control units, safety modules, terminal blocks) using standardized fixing elements. This multi-functional design allows a single housing to serve multiple mounting purposes, simplifying the installation process and reducing assembly complexity.
3Area of stationary object
If electrical components are densely packed to save space, then space utilization improves, but the risk of bacterial growth and contamination increases
Solution Approach 1:
The housing design incorporates localized protective features including sealing elements at component interfaces, drainage paths in low areas, and air gap configurations between adjacent components. These local quality enhancements create micro-environments that prevent water accumulation and bacterial growth while maintaining dense packing of electrical components within the housing structure.
Solution Approach 2:
The housing design converts the potential harm of dense packing (increased contamination risk) into a benefit by implementing integrated drainage paths and air gap features that actively manage moisture and prevent bacterial growth. The close proximity of components is maintained while using the housing structure itself to create protective airflow patterns and drainage channels that eliminate standing water.
4Ease of manufacture
If a standardized housing design is used for all component types, then manufacturing cost decreases, but adaptability to different component configurations is reduced
Solution Approach 1:
The housing design employs universal mounting brackets, standardized fixing element patterns, and modular internal support structures that can accommodate different component types and configurations. The same basic housing shell and mounting system can be used for various combinations of voltage converters, control units, safety modules, and terminal blocks, maintaining manufacturing simplicity while providing configuration flexibility.
Solution Approach 2:
The housing is designed with segmented internal support structures and modular mounting sections that can be independently configured for different component types. This segmentation allows the standardized housing shell to be adapted to various component layouts through reconfiguration of internal supports and mounting positions, providing versatility without requiring custom housing designs for each component combination.
Data Source
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Figure 3~6
Figure 7~8
AI summary
Housing (1) for electrical components of a motor vehicle (100) constituting a support for at least two or at least three electrical components, in particular at least two or at least three components from among: - a first 48V-12V voltage converter (4), - a second 48V-12V voltage converter (5), - an engine control unit (2), - a heater control unit (3), - a 12V battery safety module (7), and - an electrical terminal block (6), the housing comprising: - elements (E4, E5, A3, A4, A5, A6, C2, C3, C4, C5, 81, 82, 83, 84, 85, 86, AB, BC, CD, DA, 131, 132, 133, 134) for fixing the electrical components to the housing, and - elements (E1, E2, E3) for fixing the housing to a mounting structure (110) of a motor vehicle.