Controller Enclosure Asymmetry for Mold Core Removal
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Solution Overview
Problem
Existing vehicle controller enclosures often fail to securely hold circuit boards, leading to noise generation, water intrusion, and increased circuit board size and cost due to inadequate sealing and support mechanisms.
Innovation Solution
A controller-enclosure assembly featuring a unique enclosure design with spaced support members and apertures for terminal pass-through, allowing for secure mounting and reduced board size, while preventing rattling and water infiltration through a snap-fit connection and strategically positioned walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the enclosure uses a conventional design with support members facing each other, then the circuit board can be held securely, but the mold core cannot be removed without risk of die lock
Solution Approach 1:
The enclosure member employs asymmetric wall spacing where the first and second walls are spaced apart by a distance that increases in a direction towards the opening. This asymmetric configuration creates clearance that allows the mold core to be withdrawn without die lock, while still providing effective support members for securing the circuit board.
2Object-generated harmful factors
If the enclosure uses closely spaced support members, then the circuit board is held tightly and rattling is prevented, but the circuit board size must be increased to accommodate the support structure
Solution Approach 1:
The support members are positioned at different longitudinal locations within the enclosure, utilizing the longitudinal dimension to provide stable support. This dimensional arrangement allows effective rattling prevention without requiring increased circuit board area, as the support is distributed along the length rather than requiring lateral expansion.
3Ease of manufacture
If the enclosure uses a single-piece design, then manufacturing is simplified, but water sealing against rain, condensation, and kickup is insufficient
Solution Approach 1:
The enclosure is divided into a first enclosure member and a second enclosure member that mate together. The first enclosure member contains the circuit board and support members, while the second enclosure member includes apertures for terminal pass-through and provides sealing functionality. This segmentation enables effective water sealing while maintaining manufacturing simplicity.
Data Source
AI summary
In an aspect, an enclosure member for a circuit board includes first, second, third, fourth and fifth walls that define an interior. The first and second walls face each other. The third and fourth walls face each other. The fifth wall faces an opening. The first and second support members face the second wall. The second support member is spaced longitudinally from the first support member. The first and second walls are spaced apart by a distance that increases towards the opening. Any surfaces in the interior that at least partially face the second wall have a distance from the second wall that does not decrease towards the opening. The interior is free of surfaces that face the fifth wall and are perpendicular to the second wall thereby preventing die lock during molding, while providing the enclosure member with first and second support members that are spaced longitudinally.