Automotive Display Assembly Internal Casing Thermal and EMC Design

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Solution Overview

Problem

Current display assemblies for automotive vehicles face issues with thermal dissipation, mechanical stiffness, mura effect, electromagnetic compatibility, and high assembly costs due to the use of screws, which introduce tension and are time-consuming to produce.

Innovation Solution

A display assembly design that combines a plastic housing with a die cast metallic internal casing, using axially retaining members and positioning members to securely clip the printed circuit board and display module in place, eliminating the need for screws and enhancing thermal dissipation, mechanical stiffness, and electromagnetic compatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If screws are used to fix the display module in the housing, then the assembly is secure, but the screws introduce tension on the display module causing mura effect and require many screws which are time-consuming to assemble

Engineering Contradiction:
Improvefixation securityVSAvoidassembly time
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent removes the screw fixation system entirely and replaces it with a clipping mechanism integrated into the housing structure. The display module is retained by friction-fit clips that engage with corresponding features on the module, eliminating the need for multiple screws and reducing assembly time while maintaining secure fixation without introducing tension that causes mura effect.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical screw-threaded hole system with a friction-fit clipping mechanism. The clips are molded into the housing and engage with recesses or features on the display module, providing secure retention through friction and geometric interlocking rather than threaded mechanical fastening, thereby eliminating assembly time consumption and mura effect.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If screws are used to fix the display module in the housing, then the assembly is secure, but many screws are required which generate significant assembly cost

Engineering Contradiction:
Improvefixation securityVSAvoidassembly cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates the screw fixation system and replaces it with integrated clipping features molded directly into the housing. This reduction in part count (from multiple screws to integrated clips) significantly reduces assembly cost while maintaining secure fixation through the clipping mechanism.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the retention function previously performed by separate screw fasteners into the housing structure itself through integrated clipping features. This consolidation eliminates the need for additional screws and reduces assembly steps, thereby reducing manufacturing cost while maintaining fixation security.

Inventive Principle:
Principle #5Merging (Combining)

3Temperature

If a die cast metallic housing is used, then it acts as a heat sink for thermal dissipation, but it lacks sufficient mechanical stiffness to ensure good planarity and avoid mura effect

Engineering Contradiction:
Improvethermal dissipationVSAvoidmechanical stiffness
Core Design Contradiction:
TemperatureVSStrength

Solution Approach 1:

The patent employs a composite construction where a plastic housing provides the outer structure and thermal management, while an internal metallic support frame or stiffening ribs provide the necessary mechanical stiffness and planarity. This composite approach allows the housing to function as a heat sink while the internal metallic structure prevents deformation that would cause mura effect.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent segments the housing structure into functional components: an outer plastic housing for thermal dissipation and an internal metallic support structure for mechanical stiffness. This segmentation allows each material to perform its optimal function - the plastic for heat sinking and the metal for structural rigidity and planarity maintenance.

Inventive Principle:
Principle #1Segmentation

4Ease of manufacture

If the housing is made of plastic material, then it is cost-effective and easy to manufacture, but it lacks the electromagnetic shielding required for good EMC performance

Engineering Contradiction:
Improvemanufacturing costVSAvoidelectromagnetic compatibility
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent combines plastic housing material with metallic components (such as an internal frame, shielding layers, or metallic clips) that provide electromagnetic shielding. The plastic provides cost-effective manufacturing and thermal dissipation, while the integrated metallic elements provide the necessary EMC performance through their conductive properties.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent introduces metallic shielding elements as intermediary components between the external environment and the sensitive electronic components housed within. These metallic features (frames, clips, or shielding layers) act as electromagnetic barriers while the plastic housing maintains cost-effectiveness and ease of manufacture.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 provides a reliable, cost-effective display assembly with improved planarity, reduced assembly time, and enhanced thermal management and electromagnetic shielding, preventing the mura effect and simplifying the assembly process.

Implementation Method 1

The internal casing acts as a heat sink to help with thermal dissipation from the printed circuit board and the electronic component mounted on the printed circuit board

Methodology Applied
Scientific EffectHeat sink: Heat Sink

Implementation Method 2

The internal casing also provides shielding to ensure electromagnetic compatibility

Methodology Applied
Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentEP3441254B1Display assembly with an internal casing
Publication Date: 2020.12.02 APTIV TECHNOLOGIES LTD
  • EP3441254B1 patent drawingFigure 1
  • EP3441254B1 patent drawingFigure 2~4
  • EP3441254B1 patent drawingFigure 5

AI summary

The invention relates to a display assembly (10) for an automotive vehicle comprising a housing (12) having a front opening (22), a peripheral wall (24), and a rear wall (26) arranged along a main axis (A1), said housing (12) being configured to receive a display module (18), such as a liquid crystal display module, on a front opening side and to contain a printed circuit board (16) which is connected to the display module (18) and which includes an electronic control unit to control the display module (18), characterized in that it further comprises an internal casing (14) which is mounted in the housing (12) against the housing rear wall (26), said internal casing (14) comprising a first holding surface (42) configured to receive the printed circuit board (16) and a second holding surface (44) configured to receive the display module (18), and in that the housing (12) comprises a first set of axially retaining members (46) holding the printed circuit board (16) on the first holding surface (42) and a second set of axially retaining members (72) holding the display module (18) on the second holding surface (44).