Laser Weld Sealed Electronic Controller Housing
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Solution Overview
Problem
Electronic controllers face issues with leaks due to gasket failure, which compromises the sealing of electronic components from moisture, oils, automatic transmission fluid, chemicals, and debris.
Innovation Solution
The use of a laser weld to connect a lower sub-assembly to the housing eliminates the need for gaskets and fasteners, providing a sealed connection and reducing costs, with optional thermal management through a metal core and adhesive bonding of electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaskets and fasteners are used to connect the base plate to the housing, then the assembly is easier to manufacture with conventional methods, but the sealing reliability deteriorates due to gasket failure and potential leaks
Solution Approach 1:
The patent merges the base plate and housing into a single integrated structure where the base plate is laser-welded directly to the housing, eliminating the need for separate gaskets and fasteners. This integration resolves the contradiction by achieving both high sealing reliability through direct welding and reduced assembly complexity by removing multiple components.
Solution Approach 2:
The patent replaces the mechanical connection system (gaskets and fasteners) with a laser welding process. This substitution resolves the contradiction by providing superior sealing reliability through direct metal-to-metal fusion while reducing assembly complexity by eliminating the need to install and seal multiple separate components.
2Reliability
If gaskets are used to provide sealing between the base plate and housing, then the sealing function is achieved, but the manufacturing cost increases due to gasket materials and assembly steps
Solution Approach 1:
The patent extracts and removes the gasket component from the assembly system entirely. By eliminating the gasket and using direct laser welding between the base plate and housing, the invention achieves leak prevention through a more reliable welded joint while reducing manufacturing cost by removing material costs and assembly steps associated with gaskets.
Solution Approach 2:
The patent replaces the gasket-based sealing system with a laser welding system. This substitution resolves the contradiction by providing superior leak prevention through direct metal fusion while reducing manufacturing cost by eliminating gasket material costs, installation labor, and associated assembly complexity.
3Strength
If multiple fasteners are used to connect the housing to the base plate, then the mechanical strength is sufficient, but the assembly time and production efficiency decrease
Solution Approach 1:
The patent merges multiple fastening operations into a single laser welding process. By directly welding the base plate to the housing, the invention achieves equivalent or superior connection strength while dramatically increasing assembly speed and production efficiency by eliminating the need to install multiple individual fasteners.
Solution Approach 2:
The patent replaces the mechanical fastening system (multiple screws or clips) with a laser welding system. This substitution resolves the contradiction by providing sufficient connection strength through direct metal fusion while significantly improving productivity by reducing the number of assembly steps and operations required.
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 effectively prevents the ingress of moisture, oils, ATF, and chemicals while offering thermal and electrical conductivity, reducing the risk of leaks and lowering production costs.
Implementation Method 1
The lower sub-assembly is connected to the housing at the connection area using a laser weld
Implementation Method 2
The metal core is used to provide heat dissipation and function as an electrical conductor
Implementation Method 3
the metal core may be attached to the lower sub-assembly using an adhesive, such as a thermally conductive adhesive
Data Source
AI summary
An electronic controller having a housing, and a lower sub-assembly connected to a housing through the use of a laser weld, eliminating the use of a gasket and fasteners. The laser weld provides a sealed connection between the housing and the lower sub-assembly, preventing debris, moisture, oils, ATF, and chemicals from entering the housing, which protects the electrical components located inside the housing. The elimination of the gasket and fasteners also reduces the cost of the electronic controller. Depending upon the application, the electrical components may be mounted directly to the lower sub-assembly, or the electrical components may be mounted on a metal core. The metal core is used to provide heat dissipation and function as an electrical conductor. The lower sub-assembly may either be overmolded around the metal core, or the metal core may be attached to the lower sub-assembly after the lower sub-assembly has been formed.