Thermally Decoupled Coil Module Assembly for Bi-Directional Clutch

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Solution Overview

Problem

Conventional selectable one-way clutches with electromagnetic actuators face challenges in modularity and thermal management, leading to increased complexity and cost due to the need for separate electronic modules to isolate from high operating temperatures.

Innovation Solution

An integrated electromagnetic actuator module with a thermally decoupled housing that includes a coil module assembly and a printed circuit board (PCB) within a common housing, allowing for reduced wiring and improved packaging by minimizing the number of welded connections and enabling the PCB to be closer to the coil unit, thus mitigating thermal effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the PCB and coil unit are integrated into a common housing, then device complexity is reduced and modularity is enhanced, but the PCB is exposed to high operating temperatures that can cause thermal damage

Engineering Contradiction:

Improveassembly complexityVSAvoidthermal damage to PCB

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The common housing is segmented into a coil housing portion and an electronics housing portion, creating distinct thermal zones. The thermally decoupled housing portion acts as a separator that divides the housing structure while maintaining overall integration, allowing the PCB to be housed in a thermally isolated section away from the high-temperature coil unit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermally decoupled housing portion serves as a thermal intermediary or barrier between the coil unit and the PCB. This intermediate structure prevents direct thermal coupling while maintaining mechanical integration, allowing heat from the coil unit to be blocked from reaching the PCB through the housing structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If the PCB is placed closer to the coil unit in an integrated module, then packaging space is reduced and wiring is minimized, but thermal effects from the coil unit increase and may damage the PCB

Engineering Contradiction:

Improvepackaging spaceVSAvoidoperating temperature of PCB

Core Design Contradiction:

Area of stationary objectVSTemperature

Solution Approach 1:

Different portions of the common housing have different thermal properties. The coil housing portion is designed to withstand high temperatures and is positioned adjacent to the coil unit, while the electronics housing portion is thermally decoupled to maintain lower temperatures suitable for the PCB. This local differentiation of thermal characteristics allows close proximity integration while protecting temperature-sensitive components.

Inventive Principle:

Principle #3Local quality

3Temperature

If a separate electronic module is used to isolate the PCB from the coil unit, then thermal management is improved, but device complexity and assembly cost increase

Engineering Contradiction:

Improvethermal isolation of PCBVSAvoidmodule complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The coil unit and PCB are merged into a single integrated coil module assembly housed within a common housing, rather than using separate modules. The thermally decoupled housing portions enable this merging by providing internal thermal management within the unified structure, eliminating the need for separate electronic modules while maintaining thermal protection.

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration enhances modularity, reduces assembly components, and improves thermal management by allowing the PCB and coil unit to be integrated into a single unit, reducing the risk of heat damage and simplifying the assembly process while maintaining reliable operation.

Implementation Method 1

a coil unit disposed in the coil housing portion

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a thermally decoupled housing portion, a coil unit disposed in the coil housing portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10562387B2Coil module assembly with thermally decoupled solenoid and circuit

Publication Date: 2020.02.18 MAGNA POWERTRAIN INC(CA)

AI summary

The subject disclosure relates to a coil module assembly for a bi-directional clutch assembly having at least one active clutch. The coil module assembly includes a housing having an actuator housing portion and a PCB housing portion. An electromagnetic actuator is disposed in the actuator housing portion for effectuating pivotal movement of the active strut from an unlocked position to a locked position in response to an energization of the electromagnetic actuator. An integrated printed circuit board (PCB) is disposed in the PCB housing portion and is in electrical communication with the electromagnetic actuator for selectively energizing the electromagnetic actuator. The housing further includes a thermally decoupled housing portion which is disposed between the actuator housing portion and the PCB housing portion for thermally decoupling, i.e., reducing heat transfer, from the electromagnetic actuator to the PCB during selective energization of the electromagnetic actuator.