Sealing Adapter Bushing Assembly for Misaligned EV Power Modules
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Solution Overview
Problem
Existing power control modules in electric vehicles face challenges in preventing the ingress of elements, such as dust and water, due to misalignments between the housing and terminals, which can compromise their weather resistance and operational reliability.
Innovation Solution
A sealing adapter bushing assembly is introduced, comprising an adapter bushing base, terminal seal, and housing seal, designed to securely engage with the power control module's terminals and housing, utilizing multiple seals to compensate for misalignments while maintaining weather resistance, with an IP code rating of at least 67, ensuring dust-tight and water-tight conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional housing and terminal connections are used in power control modules, then the structure is simple, but misalignments between housing and terminals allow ingress of dust and water, compromising weather resistance
Solution Approach 1:
A sealing adapter bushing assembly is introduced as an intermediary component between the housing and terminals. This adapter bushing includes multiple seals (first seal, second seal, third seal) that create barrier layers to prevent ingress of elements. The adapter bushing mediates the connection while maintaining IP67 weather resistance despite misalignments.
Solution Approach 2:
The sealing structure is segmented into multiple functional seals rather than a single seal. The first seal engages the terminal, the second seal engages the housing, and the third seal provides additional sealing. This segmentation allows each seal to address specific misalignment issues independently, improving overall weather resistance.
2Reliability
If multiple seals are used to compensate for misalignments, then weather resistance is maintained, but the device complexity increases
Solution Approach 1:
Multiple seals and sealing functions are merged into a single integrated sealing adapter bushing assembly. This assembly includes the adapter bushing base, multiple seals, and engagement features all combined in one component that attaches to the housing, simplifying installation while maintaining IP67 protection.
Solution Approach 2:
The sealing adapter bushing assembly serves multiple functions simultaneously: it seals against dust and water, compensates for vertical and horizontal misalignments, provides mechanical support for terminals, and maintains the IP67 rating. This multi-functionality reduces the need for separate components.
3Adaptability or versatility
If rigid sealing structures are used, then manufacturing precision can be maintained, but the structure cannot accommodate misalignments between housing and terminals
Solution Approach 1:
The sealing structure uses flexible seal elements (elastomeric or rubber seals) within the adapter bushing assembly. These flexible seals can deform to accommodate vertical and horizontal misalignments between the housing and terminals while maintaining the sealing barrier, providing tolerance to positioning variations.
Solution Approach 2:
The adapter bushing assembly is designed with built-in compliance features that anticipate and cushion against misalignments before they cause sealing failures. The flexible seals and adapter design provide a cushioning effect that absorbs positioning variations, ensuring the IP67 rating is maintained despite manufacturing tolerances.
Data Source
AI summary
A sealing adapter bushing assembly for a power control module (PCM) in an electric vehicle (EV) includes an adapter bushing base, configured to be received within an opening in a housing of the PCM; a terminal seal engaged with a surface of the adapter bushing base and is configured to engage a surface of a terminal of the PCM; and a housing seal engaged with a surface of the adapter bushing base and is configured to engage a surface of the housing.