Automotive Control Unit Connector Securing and Watertightness
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Solution Overview
Problem
Existing automotive control units face challenges in ensuring durability against high external forces and maintaining watertightness in severe environments, with existing connector securing mechanisms either allowing water ingress or being prone to board dislocation under external loads.
Innovation Solution
The automotive control unit features a configuration with a first connector secured externally to the housing and a second connector secured both to the board and internally to the housing, using epoxy-based and silicon-based adhesives respectively, along with a heat-radiating housing and a mechanism to prevent unit turning, ensuring robustness and watertightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a screw mechanism is used to secure the connector through the housing, then the connector can be firmly secured, but water can ingress through the screw portion passing through the housing
Solution Approach 1:
The screw mechanism is extracted from the housing structure and replaced with an external connector securing method. The connector is secured from the outside of the housing using a screw that does not penetrate the housing, thereby eliminating the water ingress pathway while maintaining securing strength.
Solution Approach 2:
A seal member (grommet) is introduced as an intermediary between the screw and the housing interior. This seal member prevents water from penetrating through the screw hole while allowing the screw to secure the connector firmly to the housing.
2Ease of operation
If the connector is inserted into the board, then the connector can be connected, but external force causes the board to turn and dislocate
Solution Approach 1:
A positioning protrusion is provided on the board at the connector mounting position before connector insertion. This positioning structure pre-establishes the correct position and orientation, preventing board dislocation when external force is applied during connector insertion or removal operations.
Solution Approach 2:
The positioning protrusion creates an asymmetric structure that allows connector insertion in one direction while preventing reverse movement or dislocation. The asymmetric shape ensures the board maintains its position and cannot be easily dislocated by external forces applied during connector operations.
3Reliability
If multiple connectors and securing mechanisms are provided, then connecting reliability is improved, but the configuration becomes complicated and assembly becomes difficult
Solution Approach 1:
The positioning function and connector mounting function are merged into a single integrated structure. The positioning protrusion simultaneously serves as both a positioning element and a mounting reference, eliminating the need for separate positioning mechanisms and reducing overall configuration complexity while maintaining high connecting reliability.
Solution Approach 2:
The housing structure is designed with multi-functionality, where the same housing serves as both the protective enclosure and the mounting structure for connectors. The external securing method allows the housing to provide both structural support and connector mounting functions, simplifying the overall design while ensuring reliable connections.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
An automotive control unit having two connectors is provided in an uncomplicated configuration that allows holding durability to be ensured against high external force upon insertion of the connectors, watertightness in a severer environment, and high reliable connecting portions. The automotive control unit includes a board 100 on which an electronic device is mounted; a first connector directly inserted into and attached to a device to be controlled; a second connector 200 for connecting to another control unit; and a housing which houses and holds the board and includes a cover 130 and a case 500 to which the first and second connectors 300 and 200, respectively, are attached. The first connector 300 is configured to be secured to the housing from the outside of the housing. The second connector 200 is held by and secured onto the board and then secured to the housing from the inside of the control unit.