Capacitor Mounting Structure for Tolerance Fit and Rattle Prevention

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Solution Overview

Problem

Existing capacitor mounting structures in electronic control units face issues with accommodating large tolerances in capacitor diameter and distance between holding elements, leading to potential gaps, rattle noise, and plastic deformations or fractures due to over-stressing of holding elements.

Innovation Solution

A mounting structure with an arc-shaped guide, pairwise arranged support elements, alignment support, holding elements, limit stop, and chamfers on the housing part to facilitate smooth insertion and secure positioning of capacitors, ensuring form-fitting contact and stability across varying tolerances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If holding elements are used to secure capacitors with large tolerances, then adaptability to different capacitor sizes is improved, but the holding elements are overstressed leading to plastic deformations or fractures

Engineering Contradiction:

Improveadaptability to capacitor size variationsVSAvoidholding element strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent introduces a cushioning element positioned between the holding element and the capacitor body. This cushioning element absorbs excess stress when capacitors with larger-than-expected dimensions are installed, preventing the holding element from being overstressed. The cushioning material is specifically selected to be compressible and resilient, allowing it to deform elastically under load while protecting the holding element from permanent deformation or fracture.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent changes the physical state of the mounting system by introducing a compressible cushioning layer that can dynamically adjust its compression level based on the capacitor dimensions. This allows the system to accommodate a range of capacitor sizes (parameter variation) while maintaining adequate holding force without exceeding the holding element's stress limits.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If holding elements are spaced further apart to accommodate larger capacitors, then adaptability is improved, but gaps and rattle noise occur with smaller capacitors

Engineering Contradiction:

Improveaccommodation of capacitor size variationsVSAvoidgaps and rattle noise

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies different functional qualities to different parts of the mounting structure. The cushioning element provides localized compliance and fill capability at the contact points between the holding element and capacitor, while the holding elements themselves maintain their spacing for larger capacitors. This local differentiation allows the system to maintain both adaptability and stability across different capacitor sizes.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cushioning element acts as an intermediary between the holding element and the capacitor body. It fills gaps when capacitors are smaller than maximum dimensions, preventing rattle noise and instability, while still allowing the holding elements to be spaced adequately for larger capacitors. The intermediary material transmits holding forces while accommodating dimensional variations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a separate mounting structure is used to secure capacitors, then mounting reliability is improved, but device complexity increases

Engineering Contradiction:

Improvemounting reliabilityVSAvoidmounting structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the mounting structure with the housing by integrating the holding elements and cushioning elements directly into the housing structure. This merging eliminates the need for separate mounting brackets or assemblies, reducing overall device complexity while maintaining reliable capacitor securing. The holding elements are formed as integral parts of the housing, and the cushioning elements are inserted into recesses in the housing.

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 allows for efficient and secure mounting of capacitors with large tolerances, preventing plastic deformations and ensuring reliable retention without overstressing the holding elements, maintaining performance from minimum to maximum worst-case scenarios.

Implementation Method 1

a chamfer at a free end of an arc shaped guide, wherein the arc shaped guide is formed in the bottom of the housing part

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

at least one pair of holding elements, wherein the at least one pair of holding elements are elastic

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4270427A1Mounting structure for a capacitor and method for assembling a capacitor to a mounting structure

Publication Date: 2023.11.01 VEONEER SWEDEN SAFETY SYST AB

Figure 1
Figure 2~3
Figure 4~5

AI summary

The invention relates to a mounting structure (3) for a capacitor (4) in a housing part (9) and a method for mounting a capacitor (4) to a mounting structure (3) of a housing part (9). At least chamfers (40) are provided at the arc shaped guide (34), the pairwise arranged support elements (6), each of the holding elements (13) and at the alignment support (7). The chamfers (40) enable a stumbling free and smooth insertion of the capacitor in a X-direction (X) into the mounting structure (3).