Vehicle Control Unit Thermal and Vibration Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control devices for navigation systems and automated driving face challenges in efficient heat dissipation and vibration management, particularly in large series production and high-reliability applications, where manufacturing costs and weight optimization are critical.
Innovation Solution
The control device design incorporates a heat-conducting element as an insert in a plastic housing element, with thermal connection to a metal support, and separates heat-generating and sensor components onto different circuit carriers, using a mechanical floating connection and vibration-damping materials to optimize heat dissipation and minimize vibration transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If heat-generating components and sensor elements are arranged on the same circuit carrier, then device complexity is reduced, but sensor functionality is compromised due to heat interference
Solution Approach 1:
The circuit carriers are segmented into functionally separate zones: a first circuit carrier for heat-generating components (RF amplifier, mixer) and a second circuit carrier for sensitive sensor elements (accelerometer, gyroscope). This spatial segmentation prevents thermal interference while maintaining overall device integration.
Solution Approach 2:
Sensitive sensor elements are extracted from the heat-generating circuit carrier and placed on a separate second circuit carrier. This extraction isolates the sensors from thermal hazards while preserving their functionality and reducing noise interference.
2Temperature
If heat-conducting elements are used for heat dissipation, then temperature control is improved, but manufacturing complexity increases
Solution Approach 1:
The housing elements are merged with heat-conducting functionality by integrating heat-conducting inserts directly into the housing structure. This combines mechanical support and thermal management functions into a single integrated component, improving heat dissipation without adding separate cooling systems.
Solution Approach 2:
The housing elements serve multiple functions: structural support, electromagnetic shielding, and heat conduction. By making the housing multi-functional, the patent avoids additional dedicated heat-sinking components and simplifies the overall manufacturing process.
3Stability of the object's composition
If circuit carriers are rigidly connected for stable mounting, then mechanical stability is improved, but vibration transmission to sensors increases
Solution Approach 1:
Vibration-damping intermediary elements are introduced between the first and second circuit carriers. These intermediaries decouple the rigid mechanical connection, preventing vibration transmission from heat-generating components to sensitive sensors while maintaining electrical connectivity.
Solution Approach 2:
The housing and mounting structures utilize composite material approaches, combining rigid materials for structural stability with vibration-damping materials for isolation. This composite approach achieves both mechanical stability and vibration protection simultaneously.
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 enables effective heat dissipation and improved sensor functionality by ensuring rapid and reliable cooling of heat-generating components while reducing vibrations, thus enhancing the overall performance and reliability of the control device.
Implementation Method 1
the at least one heat-generating component (1) is thermally connected to a heat-conducting element (30)
Implementation Method 2
the second circuit carrier (17) is connected to the housing (13) essentially exclusively by means of vibration-damping elements (53)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a control unit (10; 10a to 10d), in particular for vehicle navigation, comprising a housing (13) consisting of at least two housing elements (11, 12; 61, 65, 72; 75), at least one circuit carrier (16; 16a; 64; 81) on which at least one heat-generating component (1) is arranged, a metal heat-conducting element (30; 61) for dissipating the heat generated by the at least one heat-generating component (1), at least one sensor element (40, 41) which is at least indirectly connected to the at least one circuit carrier (16; 16a; 64; 81), and at least one plastic connector body (35) with connecting elements (36) for electrically contacting the at least one circuit carrier (16; 16a; 64; 81), wherein the connector body (35) is made of plastic existing, frame- or lid-like housing element (12; 65; 75) integrally with this or as a component of the housing element (12; 65;75) is formed as a separate component.;