Motor Electronics Connection Device with Segmented Housing
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Solution Overview
Problem
Existing connection devices for electric motor electronics in vehicles face issues with mechanical loads, environmental influences like temperature and humidity, leading to corrosion, high contact resistance, and mechanical instability, which can result in short circuits and damage to the on-board network or motor electronics, while also restricting the use of printed circuit boards due to integrated sealing and strain relief functions.
Innovation Solution
A connection device with a separate contact adapter that includes injection molded current rails within an insulating housing, providing electrical insulation and mechanical stability, allowing for the use of printed circuit boards and enabling reliable sealing and strain relief, thus enhancing design flexibility and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing and strain relief functions are integrated into the injection molded lead frame, then reliable sealing and strain relief are achieved, but the use of printed circuit boards is restricted and design flexibility is severely limited
Solution Approach 1:
The invention divides the connection device into separate functional components: a contact adapter with current rails for electrical connections, and a connection housing with sealing and strain relief functions. This segmentation allows the use of printed circuit boards in the motor electronics while maintaining reliable sealing and strain relief, thereby resolving the contradiction between sealing reliability and design flexibility.
2Reliability
If connection contacts are provided in a connection terminal with electrical isolation, then electrical safety is improved, but mechanical loads lead to damage and separation of electrical contacts
Solution Approach 1:
The invention combines multiple functions into the connection housing: mechanical strain relief, sealing protection, and support for electrical contacts. The housing provides mechanical strength to protect against tensile loads while maintaining electrical isolation through its insulating material and integrated sealing, thereby resolving the contradiction between electrical safety and mechanical strength.
3Adaptability or versatility
If connection device is exposed to environmental influences like temperature fluctuations and humidity, then operational flexibility is improved, but corrosion occurs leading to high contact resistance and mechanical instability
Solution Approach 1:
The connection housing creates a protected environment for the electrical contacts by providing sealing against external environmental influences such as humidity and temperature fluctuations. The insulating housing material and integrated sealing prevent corrosion and maintain contact stability, thereby resolving the contradiction between operational flexibility and contact stability.
Data Source
AI summary
A connection device for connecting a cable assembly with a plurality of cables to a printed circuit board of motor electronics arranged in a motor mounting of an electric motor, having a contact adapter with a number of current rails corresponding to the cables and with an injection molded housing, in which the current rails are embedded together in an injection molded manner, wherein the current rails protruding from the injection molded housing have first connection contacts for contacting the printed circuit board and second connection contacts for contacting the cable ends of the cables, and a connection housing having a first housing part and a second housing part that surrounds the second connecting contacts contacting the cable ends and that is joined to the injection molded housing of the contact adapter.