Power Electronics Case Sealing With Interconnected Channels

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Solution Overview

Problem

Existing methods for sealing power electronics devices against dust and water ingress, such as using O-rings and gaskets, are labor-intensive and prone to misplacement, leading to incomplete seals and increased manufacturing time.

Innovation Solution

A method involving molding a case with interconnected channels and injecting a second material to form a continuous seal around power terminals and the baseplate interface, eliminating the need for manual placement of seals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual placement of O-rings and gaskets is used to seal power terminals and case interfaces, then the seal can be created, but the manufacturing time increases and the risk of misplacement occurs

Engineering Contradiction:

Improveseal completenessVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The sealing channels are pre-formed within the case structure during molding, and the seals are pre-positioned within these channels before final assembly. This preliminary preparation eliminates the need for manual seal placement during manufacturing, reducing time while ensuring proper positioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The case structure itself provides the sealing mechanism through integrated channels that guide and position the seals automatically during assembly. The design makes the case self-sufficient for sealing without requiring external manual intervention, reducing both time and error risk.

Inventive Principle:

Principle #25Self-service

2Reliability

If multiple separate seals are placed manually around each power terminal, then comprehensive sealing coverage is achieved, but the complexity of the manufacturing process increases

Engineering Contradiction:

Improvesealing coverageVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple sealing functions for different power terminals are merged into a single integrated sealing system. The interconnected channels allow one continuous seal material to seal multiple terminals simultaneously, reducing manufacturing process complexity while maintaining comprehensive sealing coverage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealing channel structure serves multiple functions: it guides seal material, positions seals around each power terminal, and creates sealed barriers. This multi-functional design simplifies the manufacturing process by eliminating the need for separate sealing operations for each terminal.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If hand placement of each O-ring is performed, then the seal can be positioned, but the labor requirement increases and positioning accuracy may be compromised

Engineering Contradiction:

Improveseal position accuracyVSAvoidmanufacturing ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The sealing channels act as an intermediary structure that automatically positions the seal material. Instead of direct manual placement, the channels mediate the positioning process, ensuring accurate seal placement while simplifying the manufacturing operation to a single injection action.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250227867A1Ingress protection of power electronic devices and a method for an air leakage test thereof

Publication Date: 2025.07.10 DANA TM4 ITAL SRL

AI summary

Systems and methods for a case for a power electronics device is provided herein. In one example, a method for manufacturing a case for a power electronics device includes molding the case using a first material, wherein the molding comprises molding a plurality of interconnected channels extending across a surface of the case and around a plurality of power terminal apertures of the case, and injecting a second material into the plurality of interconnected channels to form a continuous seal.