Electronic Throttle Cover Structure for High-Temperature Sensor Cooling
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Solution Overview
Problem
Electronic throttles face challenges in maintaining the proper operation of temperature-sensitive electrical elements at high ambient and intake air temperatures, leading to potential failure and reduced service life due to inadequate thermal management.
Innovation Solution
A plastic cover with a metal body forms a closed electrical chamber, featuring support protrusions and fluid guiding elements to enhance convective gas circulation and heat dissipation, along with a cooling pipe and protrusions in the metal body for effective heat transfer, using materials like PBT and PPS to manage high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical elements are mounted directly on the plastic cover without thermal management, then the structure is simple and manufacturing is easy, but the electrical elements cannot operate properly at high ambient temperatures above 160°C
Solution Approach 1:
The plastic cover is segmented into multiple functional zones: a mounting region for electrical elements, a convection passage region with support protrusions, and a fluid guiding feature region. This segmentation allows simultaneous thermal management and electrical element mounting without requiring separate cooling systems.
Solution Approach 2:
The patent combines thermal management functions (convection passages, fluid guiding features) directly into the plastic cover structure that also serves as the mounting base for electrical elements. This merging eliminates the need for separate cooling components while maintaining reliability at high temperatures.
2Reliability
If conventional plastic covers are used without thermal management features, then manufacturing is simple and cost-effective, but heat transfers from the plastic cover to the sensor causing temperature increase
Solution Approach 1:
The plastic cover incorporates local thermal management features including convection passages and fluid guiding features positioned adjacent to electrical elements. These localized features provide targeted heat dissipation without requiring complete redesign of the entire cover structure, maintaining ease of manufacture.
3Adaptability or versatility
If the electronic throttle is subjected to high ambient temperature and high intake air temperature for extended periods, then the vehicle can operate in hot environments, but the sensor will fail or be permanently damaged
Solution Approach 1:
The plastic cover is pre-designed with convection passages and fluid guiding features that establish cooling airflow paths before the electrical elements are mounted. This preliminary thermal management structure prevents heat accumulation and protects sensors from thermal damage during extended high-temperature operation.
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
The solution ensures the electrical element operates within a safe temperature range, extending the service life of the electronic throttle while maintaining a simple and cost-effective structure, capable of functioning at temperatures up to 200°C ambient and 210°C intake air temperatures.
Implementation Method 1
a passage for the circulation of a convection gas in the electrical chamber
Implementation Method 2
a cooling pipe and protrusions in the metal body for effective heat transfer
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a plastic cover (2) able to cooperate with a metal body (1) to form a closed electrical chamber, wherein an electrical element (5) is arranged on the plastic cover (2) and located in the electrical chamber, and a plurality of separate support protrusions (9, 14) are provided on an inner surface of the plastic cover (2) to support the electrical element (5) and form, between the plastic cover and the electrical element, a passage for the circulation of a convection gas in the electrical chamber. The invention further relates to a metal body (1) able to cooperate with a plastic cover (2). The invention also concerns an electronic throttle.