Breakaway-Leg Housing Assembly for ECU Load and Intrusion Protection

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Solution Overview

Problem

Existing housing assemblies for electronic control units (ECUs) in vehicles do not adequately protect against static load forces without causing damage to the ECU or the assembly, and they fail to prevent moisture and foreign particle intrusion.

Innovation Solution

A housing assembly with leg members featuring specific geometric configurations, including convex and concave portions, that allow separation from the housing structure under a predetermined static load force, while incorporating a die-cast metal housing and an overhang to protect against moisture and foreign particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the housing assembly uses rigid leg members to protect against static load forces, then the protection capability is improved, but the leg members may cause damage to the ECU or housing structure under excessive load

Engineering Contradiction:

Improveprotection capabilityVSAvoiddamage to ECU or assembly

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The leg members are segmented into multiple portions (first leg portion, second leg portion, third leg portion) with varying cross-sectional dimensions. This segmentation allows different segments to have different structural strengths, enabling the leg member to break at predetermined locations under excessive load rather than causing damage to the ECU or housing structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cross-sectional dimensions of the leg members are varied along their length, with the first cross-sectional dimension being greater than the second cross-sectional dimension. This parameter change creates predetermined break points that allow controlled failure under excessive static load, protecting the ECU while maintaining protection capability during normal operation.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the housing assembly provides comprehensive protection against static loads, then the ECU protection is improved, but moisture and foreign particles can still intrude through gaps or openings

Engineering Contradiction:

ImproveECU protectionVSAvoidmoisture and foreign particle intrusion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A seal member is introduced as a flexible barrier between the housing structure and the leg members. This seal member extends along the interface, filling gaps and preventing moisture and foreign particles from intruding while allowing the leg members to maintain their protective function against static loads.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The seal member acts as an intermediary element between the housing structure and leg members, mediating the interface to prevent harmful factor intrusion while allowing the structural components to perform their protective function. The seal member is received by a recess in the housing structure, creating a sealed interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12389559B2Housing assembly having breakaway leg members

Publication Date: 2025.08.12 ZF FRIEDRICHSHAFEN AG

AI summary

A housing assembly can include a housing structure and a plurality of leg members. At least one leg member of the plurality of leg members comprises a foot portion and at least one connecting portion. Each leg member can define a first convex portion disposed between the foot portion and the at least one connecting portion and a second convex portion disposed between the first convex portion. A radius of the first convex portion is about two times greater than a radius of the second convex portion.