Sealed Phase Terminal Interface for E-Machine Fluid Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric machines in vehicles face challenges in maintaining a robust conductive path across the interface between the stator and terminal block while preventing transmission fluid leakage from the wet environment within the e-machine housing to the dry environment outside, which affects the reliability and efficiency of the electrical connection.
Innovation Solution
The integration of a tubular body with a stator lead lug on one end and a busbar on the other, featuring a circumferential seal around the tubular body and a plug seal inside to prevent fluid leakage, forming a sealed conductive path between the stator and terminal block, and utilizing an O-ring seal and a disc-shaped plug to ensure effective sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phase terminals are sealed to prevent transmission fluid leakage, then reliability is improved, but device complexity increases due to additional seal components
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated tubular body structure. The tubular body integrates the seal housing, fluid passage, and mounting features into one component, eliminating the need for separate seal assemblies and reducing overall device complexity while maintaining reliable sealing against transmission fluid leakage.
Solution Approach 2:
The tubular body serves multiple functions simultaneously: it acts as a structural support element, provides fluid sealing, conducts electrical current, and serves as a mounting feature for the phase terminal. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while ensuring reliable sealing.
2Reliability
If a robust conductive path is maintained through the housing, then electrical conductivity is improved, but sealing capability deteriorates due to potential fluid leakage paths
Solution Approach 1:
The patent employs a nested structure where the conductive element is positioned within the tubular seal body. The conductor is nested inside the sealing structure, allowing electrical current to pass through while the outer tubular body maintains the seal against transmission fluid. This nested arrangement ensures both robust electrical conductivity and effective sealing capability.
3Reliability
If multiple seal components are used to prevent fluid leakage, then sealing effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple sealing functions into a single tubular body component that can be manufactured as one integrated part. This consolidation reduces the number of separate seal components needed, simplifying the manufacturing process and reducing assembly steps while maintaining effective sealing against transmission fluid leakage.
Data Source
AI summary
An e-machine is disclosed that comprises a stator, a terminal block, and a plurality of interface conductors. The stator is disposed inside a housing in a wet portion of the housing that contains transmission fluid. The terminal block is attached to the housing and is electrically connected to an inverter system controller of the e-machine. The terminal block is disposed in a dry portion of the housing that does not contain transmission fluid. The plurality of interface conductors each include a hollow conductive body, a stator lead lug on a first end connected to windings of the stator, and a busbar on a second end connected to the terminal block. A seal is assembled at an intermediate location in a groove on an outer surface of the hollow conductive body. A plug is assembled inside the hollow conductive body.