Universal Housing Shell for Electrical Distributor

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing housing shells for electrical distributors are not versatile enough to accommodate different manufacturing quantities and types of filling materials, requiring separate injection molding tools and increasing production and storage costs.

Innovation Solution

A generic housing shell designed to withstand high temperatures and pressures, allowing for the use of either injection molding compounds or resin casting compounds, with a closed outer wall except for penetration openings for plug contacts, enabling flexible application and cost-effective production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the housing shell is designed with through-openings for sealing with injection molding compound, then sealing is achieved, but the housing shell cannot be used for resin potting compounds and requires separate tools

Engineering Contradiction:

ImprovesealingVSAvoidapplication flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The housing shell is designed with a closed outer wall that can accommodate both injection molding compounds and resin potting compounds. By eliminating through-openings and using a closed wall design, the same housing shell structure serves multiple sealing applications, eliminating the need for separate tools and designs for different manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If different housing shells are manufactured for different applications, then specific requirements are met, but storage and production costs increase

Engineering Contradiction:

Improveapplication suitabilityVSAvoidstorage costs

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

A single universal housing shell design is implemented that can be used for both injection molding and resin potting applications. This eliminates the need to manufacture and store different housing shell variants for different applications, reducing storage costs and simplifying production while maintaining suitability for specific application requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If through-openings are provided in the housing shell, then injection molding compound can flow through, but resin potting compound escapes

Engineering Contradiction:

Improveinjection moldingVSAvoidresin escape

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The through-openings that caused resin escape are completely removed from the housing shell design. Instead, a closed outer wall is implemented that prevents resin potting compound from escaping while still allowing injection molding compounds to be properly contained and cured within the housing shell structure.

Inventive Principle:

Principle #2Taking out (Extraction)

4Object-generated harmful factors

If a closed outer wall is used, then resin escape is prevented, but injection molding through-flow openings are eliminated

Engineering Contradiction:

Improveresin escape preventionVSAvoidinjection molding process

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The patent introduces insert modules as intermediary components that provide the necessary flow openings for injection molding while maintaining the closed outer wall structure. These insert modules act as mediators that enable injection molding compound flow without compromising the closed-wall design that prevents resin escape, thus resolving the contradiction between the two manufacturing processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 housing shell maintains dimensional stability and can be used for various applications, reducing storage and production costs by allowing identical shells to be used in different processes, preventing resin escape, and simplifying tool production.

Implementation Method 1

designed such that the filler material made from injection-molding compound made from the thermoplastic elastomer can be injected into the housing shell without damage at a temperature of at least 170°C and a pressure of at least 100 bar, so that the injection-molding compound bonds firmly to the housing shell and the housing shell remains dimensionally stable

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP4446086A1Housing shell and plastic injection moulding method for manufacturing an electrical distributor with a housing shell

Publication Date: 2024.10.16 WWS TECHN & FORM & KUNST

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The invention relates to a housing shell for receiving a printed circuit board (2) with passive and/or active electrical components (3) and for receiving filler material (4) made of an injection-molded compound of thermoplastic elastomer. The housing shell (1) is made of a plastic material and is designed so that the filler material (4), made of injection-molded compound of thermoplastic elastomer, can be injected into the housing shell (1) without damage at a temperature of at least 170°C and a pressure of at least 100 bar, so that the injection-molded compound bonds firmly with the housing shell (1) and the housing shell (1) remains dimensionally stable. The housing shell (1) has an outer wall (5) in which penetration openings (6) for plug contacts (7) are provided. With the exception of the penetration openings (6) for the plug contacts (7), the outer wall (5) of the housing shell (1) is free of through-holes.