Through-Contact Element for Oil-Tight Electronic Module Integration
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Solution Overview
Problem
Current electronic control systems for transmissions face challenges such as high costs due to the use of ceramic substrates in integrated controllers exposed to high temperatures and the labor-intensive process of routing and sealing electrical lines in add-on controllers, which require more space and complex installation.
Innovation Solution
A through-connection element with a base plate and integrated submodules provides an oil-tight seal between the transmission and engine compartments, allowing for a hybrid circuit carrier that uses a printed circuit board at lower temperatures, eliminating the need for complex line routing and sealing, and integrating submodules like sensors and distributors in a material-to-material connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated control unit is used inside the transmission compartment, then the control unit is exposed to high temperatures requiring ceramic substrates, but this increases costs
Solution Approach 1:
The control unit is divided into two separate parts: a first control unit with ceramic substrate inside the transmission compartment for high-temperature components, and a second control unit with printed circuit board in the engine compartment for lower-temperature components. This segmentation allows each part to use the most cost-effective material for its temperature requirements.
Solution Approach 2:
A connection element serves as an intermediary between the two control units, providing both electrical connection and thermal isolation. This mediator allows the second control unit to operate in the cooler engine compartment while maintaining functional integration with the first control unit.
2Ease of manufacture
If an add-on control unit is used in the engine compartment, then a printed circuit board can be used, but this requires more space and complex installation with extensive line routing and sealing
Solution Approach 1:
The connection element merges multiple functions into a single component: it provides electrical connection between control units, thermal isolation from transmission oil, and mechanical mounting. This integration eliminates the need for separate cable routing and sealing operations.
Solution Approach 2:
The connection element serves multiple purposes simultaneously: it acts as an electrical connector, a thermal barrier, a mounting structure, and a sealing element. This multi-functionality reduces the overall number of components and simplifies installation.
3Ease of manufacture
If an add-on control unit is used in the engine compartment, then a printed circuit board can be used, but this increases space requirements
Solution Approach 1:
The second control unit is positioned adjacent to and integrated with the first control unit at the housing opening. This nested arrangement allows the second control unit to utilize the space at the boundary between compartments rather than requiring separate space in the engine compartment.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention presents a through-contact element (1) for arrangement between a transmission compartment (3) and an engine compartment (5). The through-contact element (1) has a base plate (9) with a recess (11) and a submodule (13, 15, 17) with electrical lines (19). The submodule (13, 15, 17) is arranged in the recess (11) in the base plate (9) and is integrally bonded in an oil-tight manner to the base plate (9). The through-contact element (1) is designed to separate the transmission compartment (3) from the engine compartment (5) in an oil-tight manner.