Airbag Controller Grounding via Segmented Plastic Housing

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Solution Overview

Problem

Conventional airbag controllers are heavy due to steel plate covers, increasing manufacturing costs and limiting compactness, as they require separate grounding and moisture prevention structures.

Innovation Solution

An airbag controller with an integrated plastic housing and a separate grounding device that connects the PCB to the vehicle body externally, eliminating the need for a steel plate cover and allowing for compact design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a steel plate cover is used for grounding, then grounding function is achieved, but weight increases

Engineering Contradiction:

Improvegrounding functionVSAvoidweight of airbag controller

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The grounding function is segmented from the housing structure. Instead of using a steel plate cover that combines both housing and grounding functions, the patent uses a separate grounding device (grounding terminal) that can be independently attached to the housing. This allows the housing to be made of lightweight plastic while maintaining grounding capability through the separate metallic grounding terminal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grounding function is extracted from the housing structure. The patent removes the steel plate cover that previously provided grounding and instead uses a dedicated grounding terminal that can be separately attached. This extraction allows the main housing to be made of plastic for weight reduction while the grounding function is fulfilled by the separate metallic terminal.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a steel plate cover is used for grounding, then grounding is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvegrounding functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite material strategy by combining plastic housing with a metallic grounding terminal. The housing is made of injection-molded plastic for cost-effectiveness and weight reduction, while the grounding terminal is made of metal to provide necessary electrical conductivity. This composite approach optimizes both cost and functional requirements.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a steel plate cover is used for grounding, then grounding is achieved, but the airbag controller height cannot be reduced

Engineering Contradiction:

Improvegrounding functionVSAvoidheight of airbag controller

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grounding terminal is designed to extend in a direction perpendicular to the housing thickness direction, utilizing the vertical space above the housing rather than increasing the housing thickness itself. This dimensional approach allows grounding functionality to be added without compromising the compact height of the main housing structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If housing and cover are separately provided, then PCB fixation is achieved, but number of components increases

Engineering Contradiction:

ImprovePCB fixationVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the housing and cover into a single integrated housing structure. The housing includes an opening that allows the PCB to be inserted and fixed, eliminating the need for a separate cover component. This integration reduces the number of components while maintaining the PCB fixation function through the housing's built-in structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is designed to perform multiple functions: it provides structural enclosure, serves as a mounting structure for the PCB through the opening, and acts as the outer casing. By making the housing multi-functional, the patent eliminates the need for separate cover and fixation structures, thereby reducing component count.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11643036B2Airbag controller for vehicle

Publication Date: 2023.05.09 HYUNDAI MOBIS CO LTD

AI summary

An airbag controller for a vehicle is proposed. In the airbag controller for a vehicle, an integrated plastic housing without a cover is used to fix a PCB, and a separate grounding device connecting the PCB positioned inside the plastic housing to a vehicle body positioned outside the plastic housing is used in the airbag controller to solve a problem of grounding. Accordingly, it is possible to make the airbag controller be slim and the overall size of the airbag controller be compact.