Electronic Control Device Terminal Positioning and Resin Sealing
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Solution Overview
Problem
Existing electronic control devices face challenges in downsized engine compartments due to increased numbers of connector circuits, leading to higher costs and reduced reliability, with insufficient consideration for component count and connector terminal reliability during resin sealing.
Innovation Solution
An electronic control device design that includes a control substrate with mounted electronic components, a sealing resin, a fixing member, and a fixing plate to position and secure terminals for external connections, integrated with a heat sink, electromagnetic shield, and vehicle mounting fixture, using materials like aluminum for reduced weight and cost, and employing thermal caulking and lead-free soldering for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of connector circuits is increased to enhance functions, then the functionality and fuel consumption enhancement are improved, but the cost and device complexity increase
Solution Approach 1:
The patent combines multiple connector terminals with the control substrate by sealing them together with resin. The fixing plate integrates multiple terminals in a fixed positional relationship, and the resin sealing merges these components into a unified structure, reducing overall device complexity while maintaining enhanced functionality
Solution Approach 2:
The resin sealing serves multiple functions simultaneously: it provides electrical insulation, mechanical fixation, environmental protection, and structural integration. This multi-functionality allows the system to handle increased connector circuits without proportionally increasing device complexity
2Reliability
If resin sealing is performed on the electronic circuit board, then the reliability is improved, but the connector terminal reliability and productivity are insufficiently considered
Solution Approach 1:
The terminals are positioned and fixed on the fixing plate before the resin sealing process. This preliminary positioning ensures that the sealing operation is straightforward and does not require complex post-processing or repositioning, thereby maintaining high productivity while achieving reliable sealing
Solution Approach 2:
The sealing process is segmented into distinct stages: terminal positioning on the fixing plate, assembly with the control substrate, and then resin sealing. This segmentation allows each stage to be optimized independently, ensuring both reliability and productivity
3Weight of moving object
If the engine compartment is downsized to expand cabin space, then the cabin comfortability is improved, but the installation space and layout difficulty increase
Solution Approach 1:
Multiple components (control substrate, connectors, terminals, and sealing resin) are merged into a single integrated electronic control device. This consolidation reduces the number of separate parts that need to be arranged in the engine compartment, simplifying layout while maximizing cabin space
4Length of moving object
If the control device is positioned closer to the engine to shorten wire harness, then the installation space is reduced, but the heat and vibration resistance requirements increase
Solution Approach 1:
The resin sealing, which provides environmental protection, is used to convert the harmful heat and vibration from the engine into manageable conditions. The sealing protects the electronic components from thermal and mechanical stress, allowing the control device to be positioned closer to the engine without compromising reliability
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 connector costs and enhances reliability by integrating components, improving heat dissipation, and maintaining electromagnetic shielding while minimizing warping and stress at solder joints, thus addressing the challenges of increased connector ratios and costs in downsized engine control devices.
Implementation Method 1
a sealing resin for sealing the control substrate
Implementation Method 2
a fixing plate for positioning and fixing the terminal with respect to the fixing member
Implementation Method 3
employing thermal caulking and lead-free soldering for enhanced reliability
Implementation Method 4
employing thermal caulking and lead-free soldering for enhanced reliability
Implementation Method 5
integrated with a heat sink, electromagnetic shield, and vehicle mounting fixture
Implementation Method 6
integrated with a heat sink, electromagnetic shield, and vehicle mounting fixture
Data Source
AI summary
Providing an electronic control device excellent in reliability with low cost. An electronic control device includes: an electronic component; a control substrate on which the electronic component is mounted; a sealing resin for sealing the control substrate; and a metal housing case at least a portion of which is sealed with the sealing resin; a terminal for electrically connecting the control substrate with an external device; and a fixing plate for positioning and fixing the terminal with respect to the housing case. After the terminal is fixed to the housing case by the fixing plate, the terminal is electrically connected to the control substrate and subsequently a portion of the terminal and the control substrate are sealed with the sealing resin.