Airbag ECU Capacitor Connector Layout for Compact Energy Storage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing energy requirements in airbag systems necessitate larger power supply capacitors, which pose challenges to the design of the Electronic Control Unit (ECU) due to size constraints and increase manufacturing costs with conventional connectors.
Innovation Solution
The airbag control apparatus utilizes parallel electrolytic capacitors with shared connectors, reducing the number of dedicated connectors by half, simplifying installation and reducing costs while maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dedicated connectors are used for each capacitor, then reliable electrical connection is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent combines multiple capacitor connections into a single integrated connector. The connector includes a bridge component that electrically connects multiple leads (first lead, second lead, third lead, fourth lead) through internal conductive paths, eliminating the need for separate connectors for each capacitor. This merging approach maintains reliable electrical connection while reducing the total number of connectors and simplifying the overall structure.
Solution Approach 2:
The connector is designed as a universal component that handles multiple electrical connections simultaneously. The bridge portion of the connector serves multiple functions by providing electrical pathways between different leads and the circuit board, making a single connector perform the work of multiple dedicated connectors. This multi-functionality reduces device complexity while maintaining connection reliability.
2Use of energy by moving object
If larger power supply capacitors are used to meet increasing energy requirements, then energy storage capacity is improved, but ECU size constraints are violated and manufacturing cost increases
Solution Approach 1:
By merging multiple capacitor connections into a single integrated connector, the patent reduces the overall space required for connector installation. This space optimization allows the ECU to accommodate the necessary energy storage capacity within its size constraints. The consolidated connector design eliminates redundant structural elements, freeing up valuable space within the compact ECU housing.
Solution Approach 2:
The patent transitions from a distributed connector architecture to a consolidated connector architecture. This structural phase transition in the connector system enables more efficient space utilization, allowing the ECU to meet both energy storage requirements and size constraints simultaneously.
3Reliability
If more connectors are used for capacitor connections, then electrical connection reliability is improved, but manufacturing cost increases and installation complexity increases
Solution Approach 1:
The patent merges multiple connection functions into a single connector assembly, reducing the total number of components that need to be manufactured and assembled. This consolidation lowers manufacturing costs by reducing part counts, simplifying the supply chain, and decreasing assembly steps while maintaining all necessary electrical connections through the integrated bridge structure.
Solution Approach 2:
The universal connector design performs multiple electrical connection functions simultaneously, eliminating the need for multiple specialized connectors. This multi-functionality reduces manufacturing complexity and cost while ensuring reliable electrical connections are maintained across all capacitor interfaces.
Data Source
AI summary
An airbag control apparatus, airbag systems, and vehicles are disclosed. The airbag control apparatus includes (i) an insulated housing including two supporting structures and two support members, (ii) two capacitors are respectively fixed in one of the two support structures, each of the two capacitors includes two leads, and the two leads of each capacitor are respectively fixed in one of the two support members, (iii) two conductive connectors, each including an integrated forming bridge and a pin, each bridge is inserted into one of the two support members, and is electrically connected with two leads fixed in a support member, and (iv) a circuit board electrically connected to the two pins of the two connectors on opposite sides of the two capacitors to the housing. By having each two leads of a total of four leads of the two capacitors share one bridge, the number of dedicated bridges is reduced by half, and the installing procedure is simplified and costs reduced.