Coated PCB Actuator Integration for Vehicle Electronics
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Solution Overview
Problem
Existing printed circuit boards for vehicle electronic function control face issues with complexity, cost, and reliability due to the need for numerous additional components like cables, wiring harnesses, and plug connections, which increase the risk of malfunctions and require more space, especially when exposed to harsh environments like transmission fluid or motor oil.
Innovation Solution
A coated printed circuit board design where the first parts of on-board electronics system connectors, actuator connections, and sensor connections are attached permanently to the board using methods like injection molding or welding, providing a complete encapsulation that eliminates the need for external connections and protects components from external effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug connections or wiring harnesses are attached to the printed circuit board to protect electronics from external effects, then the electronics are protected from fluids, but the system becomes complex, expensive, and space-consuming
Solution Approach 1:
The patent merges the protective function with the connection function by integrating plug connections and wiring harnesses directly into the printed circuit board structure. The PCB is designed with built-in connection elements that serve both as electrical connectors and as protective barriers against fluids, eliminating the need for separate protective components and reducing overall system complexity.
Solution Approach 2:
The patent employs a coating or encapsulation layer applied to the printed circuit board that acts as a flexible protective barrier. This thin film or shell protects the electronics and connection elements from fluid exposure while maintaining the compact integrated structure, avoiding the need for bulky protective housings or separate sealing components.
2Adaptability or versatility
If additional components like cables and wiring harnesses are added to enable vehicle control, then the control functionality is achieved, but the probability of malfunctions increases and more space is required
Solution Approach 1:
The patent combines multiple control functions and connection elements into a single integrated printed circuit board assembly. By merging the functions of multiple cables, connectors, and control elements into one unified structure, the system achieves the required control versatility while minimizing the number of discrete components that could potentially fail.
Solution Approach 2:
The printed circuit board is designed as a universal platform that integrates multiple control functions, sensor connections, actuator connections, and communication interfaces into a single multi-functional device. This eliminates the need for separate dedicated components for each function, reducing the overall component count and potential failure points while maintaining full control capability.
3Reliability
If integrated control devices are used to reduce the number of additional components, then the coordination of components is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the integrated control device into modular functional areas on the printed circuit board, such as separate zones for sensor inputs, actuator outputs, communication interfaces, and power management. This segmentation allows for standardized manufacturing processes and easier assembly while maintaining the integrated benefits of reduced component count and improved coordination.
Data Source
AI summary
A printed circuit board for electronic function control for a vehicle is created, comprising at least one actuator connection, of which a first part is attached to the printed circuit board and a second part extends away from the printed circuit board, and a connecting element, of which a first part is attached to the printed circuit board and a second part extends away from the printed circuit board, characterized in that the printed circuit board is coated, such that the printed circuit board and the first parts of the at least one actuator connection and the connecting element are protected, such that a seal against external effects acting on the printed circuit board is obtained. Furthermore, a system having a printed circuit board according to the disclosure is created.