Backup Power Mounting Structure for Vehicle ECU

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Solution Overview

Problem

The existing methods for fixing backup power units to electronic control units (ECUs) in vehicles face challenges with vibration, aging, and material degradation, particularly with plastic snap-fit solutions that fail to retain the power unit over time, leading to instability and potential damage to the PCB.

Innovation Solution

A backup power mounting structure featuring flexible arms with metal reinforcements that provide a form and force-fitting mechanism to securely attach the backup power unit, enhancing stability and durability, suitable for both plastic and metal housings, and allowing for easy assembly and overmolding with plastic materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the backup power unit is fixed to the PCB, then the power unit is securely attached, but the mass of the backup power unit adds stress to the PCB which might hurt the PCB

Engineering Contradiction:

Improveattachment strengthVSAvoidstress on PCB

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The mounting structure is divided into separate components: a mounting structure attached to the PCB, and flexible arms that connect the backup power unit to the mounting structure. This segmentation transfers the mechanical stress from the PCB to the mounting structure and flexible arms, protecting the PCB while maintaining secure attachment.

Inventive Principle:

Principle #1Segmentation

2Strength

If the power unit is fixed to the connector, then the power unit is attached, but undesired vibration noise is caused

Engineering Contradiction:

Improveattachment strengthVSAvoidvibration noise

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Flexible arms are used to connect the backup power unit to the mounting structure. These flexible arms act as vibration dampers, absorbing mechanical vibrations and preventing them from being transmitted to the connector and generating noise, while still maintaining secure attachment.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If plastic snap-fit solution is used to fix the backup power unit, then the assembly is easy to manufacture, but the solution fails to retain the power unit after aging

Engineering Contradiction:

Improvemanufacturing easeVSAvoidretention reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The mounting structure combines plastic components (for ease of manufacturing and integration) with metal arms (for strength and durability). This composite approach allows the plastic snap-fit to provide easy assembly while the metal arms ensure long-term retention reliability even after aging.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The flexible arms provide a dynamic mounting solution that can accommodate thermal expansion and contraction during aging, maintaining retention force over time unlike rigid plastic snap-fit solutions alone.

Inventive Principle:

Principle #15Dynamics

4Reliability

If metal arms are added to back up the flexible arms, then the retention force is maintained over time, but the device complexity increases

Engineering Contradiction:

Improveretention reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The metal arms are integrated with the plastic mounting structure to form a unified component. The metal arms extend from the plastic body, combining the manufacturing advantages of plastic injection molding with the mechanical strength of metal, thereby maintaining retention reliability without proportionally increasing complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively reduces vibration, maintains retention force over time, and prevents damage to other components by providing a strong and versatile attachment method that is independent of plastic material degradation, ensuring reliable operation across various ECU housing materials.

Implementation Method 1

at least one pair of flexible arms arranged opposite to each other for fixing the backup power unit to the backup power mounting structure in a form and force fitting manner

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4102942A1Backup power mounting structure, electronic control unit (ECU) and method for manufacturing a backup power mounting structure

Publication Date: 2022.12.14 VEONEER SWEDEN SAFETY SYST AB

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AI summary

The invention relates to an electronic control unit (1) of a vehicle (16), comprising a backup power unit (7) and at least two flexible arms (11) arranged opposite to each other for fixing the backup power unit (7) to the backup power mounting structure (10) in a form and force fitting manner. At least two metal arms (12) are provided. One metal arm (12) is in a form fitting contact with a flat portion (13) of one flexible arm (11). Another metal arm (12) is in a form fitting contact with a flat portion (13) of another corresponding flexible arm (11). An electronic control unit (1) for a vehicle (16) comprises a closed housing (2) which is defined by a pot-like housing base (5) and a cover (4). Also provided is a method for manufacturing a backup power mounting structure (10) for an electronic control unit (1) of a vehicle (16).