Description:FIELD OF THE INVENTION
The embodiments of the present disclosure relate generally to a vehicle control unit and more particularly to waterproofing of vehicle control unit that effectively dissipates heat generated by internal electronic components.
BACKGROUND
The modern electric vehicle (EV) industry requires increasingly sophisticated electronic control systems to manage a wide range of functions, from battery management to advanced driver assistance systems (ADAS). Vehicle control units (VCUs) are essential for maintaining optimal performance, safety, and efficiency in EVs. As these vehicles operate in diverse environmental conditions, ensuring the reliability and integrity of their control units becomes even more critical. One of the key challenges in designing VCUs for EVs is protecting them from environmental elements, especially water, which can lead to short circuits, corrosion, and the failure of electronic components.
Traditional methods for safeguarding electronic control units involve housing them in enclosures resistant to environmental factors. However, these approaches can be bulky, costly, and often insufficient for providing long-term protection, particularly in harsh conditions such as exposure to water, humidity, dust, and varying temperatures. Moreover, in electric vehicles, the heat generated by electronic circuits within these control units must be effectively managed to prevent overheating, which could compromise both performance and the lifespan of the unit.
OBJECTS OF THE INVENTION
1. The primary objective of the present invention is to provide a vehicle control unit with a waterproof packaging design to protect internal components from water ingress and environmental contaminants.

2. Another objective of the present invention is to provide a structure comprising a bottom unit and a top unit which are press-fitted to facilitate robust waterproofing and efficient heat dissipation.

3. Another objective of the present invention is to use a liquid sealant within a specially designed groove around the periphery of the bottom unit which provides a reliable and permanent waterproof seal.

4. Another objective of the present invention is to provide a vehicle control unit that offers a combination of waterproofing, heat management, and structural integrity in a cost effective and reliable manner.
SUMMARY OF THE INVENTION
The present invention aims to provide a vehicle control unit with waterproof packaging, comprising a bottom unit configured to be a base of the vehicle control unit, comprising: a receiving portion for securing a heat sink, a bottom cover configured with a groove around its periphery for containing a liquid sealant, a first electrical circuitry mounted above the heat sink, a thermal pad sandwiched between the periphery of the first electrical circuitry and the heat sink, facilitating the transfer of heat from the first electrical circuitry to the heat sink and a main electrical circuitry secured to the bottom cover, positioned above both the heat sink and the first electrical circuitry wherein the main electrical circuitry is electrically coupled to the first electrical circuitry. A top unit comprising a protrusion along its periphery configured to fit into the groove of the bottom cover, one or more ribs on surface of the top unit to enhance the strength and durability of the vehicle control unit, wherein during assembly, a liquid sealant is introduced into the groove, and the protrusion of the top unit is press-fitted into the groove, and the liquid sealant is allowed to solidify, resulting in a non-separable assembly with complete waterproofing.
As per the first embodiment of the present invention, the heat sink is fastened to the bottom cover from the inside to dissipate heat out of the vehicle control unit.
As per the second embodiment of the present invention, the liquid sealant is introduced between the heat sink and the bottom cover before fastening.
As per the third embodiment of the present invention the heat sink includes a series of closely spaced baffles to ensure efficient heat dissipation.
As per the fourth embodiment of the present invention, the main electrical circuitry includes connectors for interfacing with a display unit and other vehicle accessories.
As per the fifth embodiment of the present invention, the main electrical circuitry is designed to control multiple vehicle functions, including battery management, transmission control, and brake systems, lighting systems, electronics systems, charging systems.
As per the sixth embodiment of the present invention, the main electrical circuitry is fastened to the bottom cover with self-tapping screws.
As per the seventh embodiment of the present invention, the groove in the bottom cover is configured to accommodate a specific volume of liquid sealant, ensuring an even distribution and complete sealing upon solidification.
As per the eighth embodiment of the present invention, the bottom cover is configured with one or more cut-outs positioned between the groove around the periphery to allow excess liquid sealant to escape.
As per the ninth embodiment of the present invention, a method of assembling the vehicle control unit for waterproof packaging comprises the steps of: pouring a liquid sealant into a groove of a bottom cover, securing a heat sink to the bottom cover, mounting a thermal pad above the heat sink, mounting a first electrical circuitry on the thermal pad, securing a main electrical circuitry to the bottom cover, press-fitting a top unit onto a bottom unit, ensuring an engagement of the top unit in a cut-out of the groove, allowing the liquid sealant to solidify.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
FIG.1 illustrates a vehicle control unit (VCU), in accordance with the present invention.
FIG. 2 is an exploded view of the vehicle control unit, in accordance with the present invention.
FIG. 3(a) is a top view of a bottom unit of the VCU after assembly, in accordance with the present invention.
FIG. 3(b) is a bottom view of a bottom unit of the VCU before assembly, in accordance with the present invention.
FIG. 3(c) is a heat sink of the VCU, in accordance with the present invention
Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, members, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
Embodiments of the present invention will be described below in detail with reference to the accompanying figures.
Referring to figure 1, a vehicle control unit (VCU) of the present invention configured with waterproof packaging is depicted. The VCU (100) mainly comprises a bottom unit (102) and a top unit (104). The bottom unit (102) forms a base and incorporates several critical elements to ensure waterproofing, efficient heat dissipation, and structural integrity. The VCU (100) of the present invention provides a compact design with IP65 waterproofing.
Referring to Figure 2, an exploded view of the VCU (100) is presented, while Figures 3(a), 3(b), and 3(c) show the top and bottom views of the bottom unit (102) and a detailed illustration of the heat sink (208). The bottom unit (102) comprises a bottom cover (202), a heat sink (208), a first electric circuitry (210) and a main electrical circuitry (214). The bottom cover (202) is configured with a groove (206) around its periphery. Additionally, the bottom cover (202) is configured with one or more cut-outs positioned between the groove (206) wherein the cut-outs are designed to allow excess liquid sealant to escape during assembly, preventing overflow and ensuring a clean and effective seal. The groove (206) is intended to contain a liquid sealant, which is a key element in creating a waterproof assembly. The dimensions of the groove (206) are specifically configured to accommodate a predetermined volume of liquid sealant, which allows for even distribution and complete sealing when the liquid sealant solidifies. The bottom cover (202) also comprises a receiving portion (204) configured to secure the heat sink (208) wherein the receiving portion (204) is also a cut-out portion. This receiving portion (204) provides a stable platform for the heat sink, ensuring it remains firmly in place for effective thermal management. The heat sink (208) is secured with fastening screws. The heat sink (208) is fastened to the bottom cover (202) from the inside of the VCU (100), plays a crucial role in dissipating the heat generated by the internal electronic components. The heat sink (208) comprises a series of closely spaced baffles (216), which increase the surface area exposed to the surrounding air, thereby enhancing heat dissipation efficiency.
The first electrical circuitry (210) is mounted above the heat sink (208). The first electrical circuitry (210) is configured for controlling various auxiliary control functions within the VCU (100). Further, a thermal pad (212) is sandwiched between the periphery of the first electrical circuitry (210) and the heat sink (208) which facilitates efficient heat transfer from the first electrical circuitry (210) to the heat sink (208), ensuring optimal thermal management.
Referring to figure 4, the bottom view of the main electrical circuitry (214) is shown along with the heat sink (208). The main electrical circuitry (214) is another vital component positioned above both the heat sink (208) and the first electrical circuitry (210). It is secured to the bottom cover (202) using self-tapping screws, which provide a robust and reliable attachment. The main electrical circuitry (214) is electrically coupled to the first electrical circuitry (210) and is configured to control multiple vehicle functions, including battery management, transmission control, brake systems, lighting systems, electronics systems, and charging systems. The main electrical circuitry (214) also includes connectors (402) for interfacing with a display unit and other vehicle accessories, making it highly versatile for various automotive applications. Additionally, bottom cover (202) also comprises one or more channels (218) to accommodate said one or more connectors (402).
Referring to figure 2 and figure 5, the top unit (104) of the VCU (100) is shown. The top unit (104) is configured with a protrusion (502) along its periphery that fits precisely into the groove (206) of the bottom cover (202). During assembly, a liquid sealant is introduced into the groove (206), and the protrusion (502) of the top unit (104) is press-fitted into this groove. The liquid sealant is allowed to solidify, forming a non-separable assembly that ensures complete waterproofing of the VCU (100). Furthermore, the top unit (104) comprises one or more ribs (504) on its surface. The said ribs (504) provide additional strength and durability to the VCU (100) by enhancing its resistance to impact and vibration, making it suitable for the demanding environments in which vehicles operate.
The assembly method of the vehicle control unit (100) for waterproof packaging is described herein onwards. The method begins with introducing a liquid sealant into the groove (206) of the bottom cover (202). The heat sink (208) is then secured to the bottom cover. The first electrical circuitry (210) is mounted above the heat sink (208) with a thermal pad (212) positioned in between. Next, the main electrical circuitry (214) is secured to the bottom cover (202) using self-tapping screws. Finally, the top unit (104) is aligned and press-fitted onto the bottom unit (102), ensuring that the protrusion (302) engages with the groove (206) filled with the liquid sealant. The solidification of the sealant completes the assembly, resulting in a robust and waterproof VCU enclosure.
While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
FURTHER ADVANTAGES OF THE INVENTION
The waterproof vehicle control unit (VCU) has several great features. It’s designed to provide a completely sealed design. The groove is introduced in the present invention that holds sealant and a top unit that press-fitted into it. The VCU also manages heat well with a heat sink and thermal pad, which keeps everything cool. It’s built to be strong and resist impacts, making it tough for harsh driving conditions. The assembly is easy, using sealant and self-tapping screws. The VCU controls many vehicle functions and connects easily to other accessories. It also handles excess sealant well, making sure everything stays sealed and clean. Overall, this VCU is compact, durable, and perfect for modern vehicles.
REFERENCES

Sr. No. Part Name Reference Number
1 Vehicle Control Unit (VCU) 100
2 Bottom Unit 102
3 Top Unit 104
4 Bottom Cover 202
5 Receiving Portion 204
6 Groove 206
7 Heat Sink 208
8 First Electrical Circuitry 210
9 Thermal Pad 212
10 Main Electrical Circuitry 214
11 Baffles 216
12 Channels on Bottom Cover 218
13 Connectors 402
14 Protrusion on Top Unit 502
15 Ribs on Top Unit 504

, Claims:We Claim:
1. A vehicle control unit (100) with waterproof packaging, comprising:
• a bottom unit (102) configured to be a base of the vehicle control unit (100), comprising:
o a receiving portion (204) for securing a heat sink (208);
o a bottom cover (202) configured with a groove (206) around its periphery for containing a liquid sealant;
o a first electrical circuitry (210) mounted above the heat sink (208);
o a thermal pad (212) sandwiched between the periphery of the first electrical circuitry (210) and the heat sink (208), facilitating the transfer of heat from the first electrical circuitry (208) to the heat sink (204); and
o a main electrical circuitry (214) secured to the bottom cover (202), positioned above both the heat sink (208) and the first electrical circuitry (210) wherein the main electrical circuitry (214) is electrically coupled to the first electrical circuitry (210);
• a top unit (104), comprising:
o a protrusion (502) along its periphery configured to fit into the groove (206) of the bottom cover (202);
o one or more ribs (504) on surface of the top unit (104) to enhance the strength and durability of the vehicle control unit (100);
wherein during assembly, a liquid sealant is introduced into the groove (206), and the protrusion (502) of the top unit (104) is press-fitted into the groove (206), and the liquid sealant is allowed to solidify, resulting in a non-separable assembly with complete waterproofing.
2. The vehicle control unit (100) of claim 1, wherein the heat sink (208) is fastened to the bottom cover (202) from the inside to dissipate heat out of the vehicle control unit (100).

3. The vehicle control unit (100) of claim 1, wherein the liquid sealant is introduced between the heat sink (208) and the bottom cover (202) before fastening.

4. The vehicle control unit (100) of claim 1, wherein the heat sink (208) includes a series of closely spaced baffles (216) to ensure efficient heat dissipation.

5. The vehicle control unit (100) of claim 1, wherein the main electrical circuitry (214) includes connectors (402) for interfacing with a display unit and other vehicle accessories.

6. The vehicle control unit (100) of claim 1, wherein the main electrical circuitry (214) is designed to control multiple vehicle functions, including battery management, transmission control, and brake systems, lighting systems, electronics systems, charging systems.

7. The vehicle control unit (100) of claim 1, wherein the main electrical circuitry (214) is fastened to the bottom cover (202) with self-tapping screws.

8. The vehicle control unit (100) of claim 1, wherein the groove (206) in the bottom cover (202) is configured to accommodate a specific volume of liquid sealant, ensuring an even distribution and complete sealing upon solidification.

9. The vehicle control unit (100) of claim 1, wherein the bottom cover (202) is configured with one or more cut-outs positioned between the groove (206) around the periphery to allow excess liquid sealant to escape.

10. A method of assembling the vehicle control unit (100) for waterproof packaging comprises the steps of:
pouring a liquid sealant into a groove (206) of a bottom cover (202);
securing a heat sink (208) to the bottom cover (202);
mounting a thermal pad (212) above the heat sink (208);
mounting a first electrical circuitry (210) on the thermal pad (212);
securing a main electrical circuitry (214) to the bottom cover (202);
press-fitting a top unit (104) onto a bottom unit (104);
ensuring an engagement of the top unit (104) in a cut-out of the groove (206);
allowing the liquid sealant to solidify.

Dated this the 14th day of October 2024