Controller Integrated Fuel Pump Module Bonding
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Solution Overview
Problem
Conventional variable pressure control fuel pump systems face challenges such as increased manufacturing costs, electrical noise, voltage drop, deformation of components, and moisture introduction due to complex electrical wirings and separate controller components, which affect the performance and reliability of the fuel pump module.
Innovation Solution
A controller integrated fuel pump module with a receiving part and flange design featuring a convexo-concave pattern on the inner surface for enhanced bonding, a dual wall structure for improved strength, and a drainage hole to prevent moisture ingress, reducing the number of components and minimizing deformation while securing robustness against moisture and electrical noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate controller with complex electrical wirings and connectors is used, then the fuel pump system can be controlled, but the manufacturing costs increase and electrical noise becomes severe
Solution Approach 1:
The controller is merged with the fuel pump module by embedding the PCB assembly into the receiving part of the flange. The PCB assembly is integrally molded with the flange, eliminating the need for separate controller housing, mounting brackets, and complex electrical connectors. This integration reduces device complexity while maintaining control functionality.
Solution Approach 2:
The flange structure serves multiple functions: it provides structural support for the fuel pump module, contains the receiving part for the PCB assembly, and integrates the controller functionality. This multi-functionality reduces the need for separate components and simplifies the overall system structure.
2Ease of operation
If the electrical wiring between controller and pump motor becomes longer, then the controller can be positioned separately, but voltage drop increases and motor performance lowers
Solution Approach 1:
The controller and pump motor are merged into a single integrated module, eliminating long electrical wirings. The PCB assembly is positioned adjacent to the pump motor within the same housing, reducing wiring length to a minimum and preventing voltage drop while maintaining operational flexibility.
3Ease of manufacture
If the PCB assembly is molded in the receiving part with a smooth inner surface, then the molding process is simple, but bonding performance is poor and moisture can be introduced
Solution Approach 1:
The inner surface of the receiving part has locally varied properties: smooth regions for easy molding and cleaning, and convexo-concave portions for enhanced bonding and moisture resistance. This local quality variation maintains molding simplicity while improving bonding performance and preventing moisture ingress.
Solution Approach 2:
The convexo-concave portions on the inner surface of the receiving part create curved geometries that enhance bonding between the PCB assembly and the flange. The curved surfaces increase surface area and mechanical interlocking, improving bonding performance while the contours help prevent moisture accumulation.
4Ease of manufacture
If the flange and receiving part are integrally molded with smooth surfaces, then manufacturing is easier, but deformation occurs under stress conditions
Solution Approach 1:
The flange and receiving part are integrally molded with locally varied surface properties. The outer surface remains smooth for ease of manufacture, while the inner surface features convexo-concave portions that provide structural reinforcement and deformation resistance under stress conditions.
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
The solution minimizes deformation and moisture introduction, enhances bonding performance, prevents short circuits and pore generation, and maintains module integrity even under stress conditions, such as capacitor explosion, thereby improving the reliability and efficiency of the fuel pump module.
Implementation Method 1
a convexo-concave portion having a shape in which recesses and bosses are repeated is formed on an inner surface of the receiving part such that a bonding force between the receiving part and the molding part is increased by the convexo-concave portion
Implementation Method 2
A drainage hole for discharging moisture existing between bonding surfaces of the receiving part and the molding part is formed on a side surface of the receiving part
Data Source
AI summary
A controller integrated fuel pump module may include a receiving part formed on an outer surface of a flange assembled in a fuel tank, a PCB assembly configured by mounting elements of a controller to a PCB, wherein the PCB assembly is molded by a molding part while being received in the receiving part, and a convexo-concave portion having a shape in which recesses and bosses, the convexo-concave portion being repeatedly formed on an inner surface of the receiving part, such that a bonding force between the receiving part and the molding part is increased by the convexo-concave portion.