Container Mechanical Tolerance Compensatory Element

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Solution Overview

Problem

Conventional containers for electronic assemblies experience mechanical stresses during manufacturing and temperature-dependent expansions due to direct attachment methods, which restrict movement of the electronic assemblies.

Innovation Solution

The introduction of a mechanical tolerance compensatory element, featuring a housing with projections and notches that allow for expansion and movement of the electronic assembly without direct attachment, combined with a flexible cover design that accommodates thermal changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the electronic assembly is directly attached to the housing using screws, then the electronic assembly is securely fixed in position, but mechanical stresses are applied to the electronic assembly during manufacturing and thermal expansion is prevented

Engineering Contradiction:

Improvepositioning stabilityVSAvoidmechanical stress

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

A compliant member is introduced as an intermediary element between the cover and the electronic assembly. This compliant member deforms elastically to accommodate dimensional variations and thermal expansions, thereby preventing direct transmission of mechanical stresses to the electronic assembly while still maintaining secure retention through the attachment members

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the electronic assembly is directly attached to the housing, then the assembly is firmly retained, but movement and thermal expansion in the x-y plane and z-axis are prevented

Engineering Contradiction:

Improveretention strengthVSAvoidthermal expansion capability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The attachment members are designed with threaded portions that engage with threaded recesses in the housing, allowing for adjustable positioning along the z-axis. This enables the system to accommodate dimensional variations and thermal expansions by adjusting the engagement depth, thereby maintaining retention strength while adapting to thermal changes

Inventive Principle:

Principle #35Parameter changes

3Strength

If screws pass through the electronic assembly to attach the cover, then the cover is securely attached, but mechanical stresses and potential damage to the electronic assembly occur

Engineering Contradiction:

Improveattachment strengthVSAvoidmechanical damage risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The attachment system is segmented into distinct functional zones: attachment members secure the cover to the housing without penetrating the electronic assembly, while the compliant member provides a separate retention mechanism that contacts the electronic assembly indirectly. This segmentation eliminates direct mechanical stress paths through the electronic assembly while maintaining secure attachment

Inventive Principle:

Principle #1Segmentation

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

This design reduces mechanical stress on the electronic assembly, enabling free movement and expansion in all directions while maintaining position, thus preventing damage from thermal fluctuations.

Implementation Method 1

The support member extends from the electronic assembly recess sidewall into the electronic assembly recess

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 2

movement of the electronic assemblies (e.g., as a result of temperature-dependent expansions) is prevented during use

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

The flexible portion is moveable relative to the central portion and extends from the slot to the outer edge

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 4

The first projection extends into the electronic assembly recess and contacts the electronic assembly such that the electronic assembly is retained between the housing and the cover

Methodology Applied

Scientific EffectMechanical retention:

Implementation Method 5

The attachment member is disposed on the attachment member portion defined by the cover and attaches the cover to the housing

Methodology Applied

Scientific EffectThreaded fastening: Screw

Data Source

PatentUS12150259B2Containers having a mechanical tolerance compensatory element

Publication Date: 2024.11.19 LEAR CORP

AI summary

A container that has a mechanical tolerance compensatory element includes a housing, an electronic assembly, a cover, and an attachment member. The housing defines an electronic assembly recess. The electronic assembly is disposed within the electronic assembly recess and contacts the housing. The cover is attached to the housing, has a center, and defines an attachment member portion, a slot, and a first projection. The slot is disposed between the attachment member portion and the center of the cover. The first projection extends into the electronic assembly recess and contacts the electronic assembly such that the electronic assembly is retained between the housing and the cover. The attachment member is disposed at the attachment member portion defined by the cover and attaches the cover to the housing.