Control Device Assembly Sealing via Segmented Frame
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Solution Overview
Problem
Existing control unit assemblies for motor vehicles are costly due to complex manufacturing processes and expensive materials, particularly in forming seals and cooling frames, which complicate the housing and sealing of control unit electronics.
Innovation Solution
A control unit assembly featuring independently formed frame elements that enclose electronic components on a printed circuit board, with a seal applied to the frame's outer peripheral surface, and a housing element that presses the seal to create a media-tight sealed electronic space, eliminating the need for complex shaping and using inexpensive housing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If die-cast parts are used for housing upper and lower parts with circumferential grooves for seals, then reliable sealing is achieved, but manufacturing cost increases significantly
Solution Approach 1:
The housing is divided into two separate parts: a housing element and an independently formed frame element. This segmentation allows each part to be manufactured using simpler, less expensive processes while maintaining the sealing function through their combined structure.
Solution Approach 2:
The independently formed frame element acts as an intermediary component between the housing element and the printed circuit board. It provides the necessary sealing surface and structural support without requiring complex die-casting processes, thus reducing manufacturing cost while maintaining sealing reliability.
2Ease of manufacture
If aluminum sheet is used for housing upper part with complex forming to create receiving groove for seal, then manufacturing cost is reduced compared to die-cast, but device complexity increases
Solution Approach 1:
The housing structure is segmented into a simple housing element and a separately manufactured frame element. This eliminates the need for complex forming of the housing element itself, reducing both manufacturing cost and structural complexity.
Solution Approach 2:
The complex receiving groove structure is extracted from the housing element and implemented as a separate independently formed frame element. This allows the housing element to remain simple while the sealing function is provided by the dedicated frame element.
3Temperature
If cooling frame is provided on which housing top and bottom parts and printed circuit board are arranged, then thermal management is improved, but manufacturing complexity increases due to complex groove forming
Solution Approach 1:
The cooling frame functionality is merged with the independently formed frame element. This integration allows thermal management to be achieved without requiring separate complex groove forming processes, as the frame element itself serves both structural and cooling purposes.
Solution Approach 2:
The independently formed frame element serves multiple functions: it provides structural support, enables sealing, and facilitates heat dissipation. This multi-functionality eliminates the need for separate cooling frame structures and complex groove forming.
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 solution allows for a simple and cost-effective housing and sealing of control unit electronics, reducing manufacturing costs and complexity while maintaining a reliable media-tight seal, enabling efficient heat dissipation and robust mechanical connections.
Implementation Method 1
the seal is urged by a housing element to form a medium-tight sealed electronic space against the printed circuit board
Implementation Method 2
the circuit board is thermally conductively connected to the frame element and the frame element is thermally conductively connected to the housing element
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a control device assembly (1; 1'), in particular for a motor vehicle, comprising a printed circuit board (2; 2') that receives the control device electronics. At least one discretely formed frame element (5; 5') is supported on a populated face (2a; 2b'; 2b; 2b') of the printed circuit board (2; 2'), enclosing at least one electronic component (3). A seal (6) sits against an outer circumferential surface (5a; 5a') of the frame element (5; 5'), said seal surrounding the circumferential surface, and the seal (6) is pressed against the printed circuit board (2; 2') by a housing element (7a, 7b; 7a', 7b') in order to form an electronic chamber (8) that is sealed in a media-tight manner.