Electronic Control Module Adapter for Short Circuit Prevention
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Solution Overview
Problem
Existing electronic control modules for transmission control face challenges in withstanding high temperature changes and metal chips in transmission fluid, particularly due to protruding connection elements that require protective measures to prevent short circuits.
Innovation Solution
The solution involves an adapter with a metal web and holding body on the printed circuit board, where the connection element is welded to the metal web using a conductive material, eliminating the need for through-plug connections and providing a stable, reliable electrical connection without protrusions, allowing for efficient assembly and reduced thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection elements are soldered into through-plugs of the printed circuit board, then electrical connection is achieved, but connection elements protrude to the underside requiring protective measures against metal chips
Solution Approach 1:
The patent transitions from traditional through-plug connections (vertical dimension) to surface-mounted connections (horizontal dimension). Connection elements are arranged parallel to the circuit board surface and connected via surface pads, eliminating protrusions to the underside and the need for protective covers.
Solution Approach 2:
The invention extracts the connection elements from the through-plug structure and repositions them on the surface of the circuit board. This separation eliminates the harmful protrusion effect while maintaining electrical connectivity through alternative surface-mounted contact paths.
2Reliability
If multiple thermal processes are applied during assembly, then electrical connections are established, but thermal stress accumulates on the printed circuit board
Solution Approach 1:
The patent combines multiple connection functions into a single thermal process. The surface-mounted connection structure allows both mechanical attachment and electrical connection to be achieved in one soldering operation, eliminating the need for separate through-plug insertion and soldering steps.
Solution Approach 2:
The invention replaces the mechanical through-plug insertion system with a surface-mounted system where connection elements are positioned and attached in a single step. This substitution eliminates the need for repeated thermal cycling associated with multiple assembly operations.
3Device complexity
If connection elements are arranged parallel to the circuit board surface, then no protrusions occur, but welding process must be used instead of traditional soldering
Solution Approach 1:
The patent changes the connection method from soldering to welding, and accordingly modifies the connection element geometry and material properties. The connection elements are designed with welding-compatible materials and geometries that facilitate direct welding to surface pads, enabling the parallel arrangement without protrusions.
Solution Approach 2:
The invention employs composite construction with connection elements made of materials suitable for welding (such as copper or copper alloys) combined with the circuit board's substrate materials. This material selection enables the welding process while maintaining electrical conductivity and mechanical strength.
4Productivity
If adapters are arranged independently of electrical components, then assembly flexibility is improved, but additional components increase device complexity
Solution Approach 1:
The patent designs adapters with multi-functional capability, serving both as mechanical support structures and as electrical connection carriers. The adapters integrate multiple functions that would otherwise require separate components, reducing overall device complexity while maintaining assembly flexibility.
Solution Approach 2:
The invention segments the circuit board into modular regions with independently arrangeable adapters and electrical components. This segmentation allows flexible assembly sequences and independent optimization of different functional areas without increasing overall system complexity.
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 approach ensures a robust and reliable electrical connection, reduces installation space, and prevents short circuits by using a welding process that aligns the connection and contact sections parallel to the circuit board, allowing for efficient assembly without additional thermal processes, and effectively manages thermal stresses and vibrations.
Implementation Method 1
the contact section (35) of the at least one metal web (34) and the connection section (25) of the at least one connection element (24) are welded to one another in the overlapping area
Implementation Method 2
the at least one metallic web or the at least one connection element is applied by means of an electrically applied to the at least one contact surface conductive material are electrically contacted with the at least one contact surface
Data Source
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AI summary
For an electronic control module (1), in particular for a transmission controller, comprising a printed circuit board (5) with a component side (17), on which at least one contact area (13a) is arranged, and comprising at least one electrical component (20) with at least one electrical connection element (24) having a connection section (25) which runs parallel to the component side (17) of the printed circuit board (5) and is electrically connected to the at least one contact area (13a), it is proposed to arrange at least one adapter (30) on the printed circuit board (5), which adapter is independent of the at least one electrical component (20), is arranged as a separate part on the printed circuit board (5) and has a holding body (31) fastened to the printed circuit board (5) outside the at least one contact area (13a) and at least one metal web (34) which is arranged on the holding body (31) and has a contact section (35) running parallel to the component side of the printed circuit board, wherein the contact section (35) of the at least one metal web (34) and the connection section (25) of the at least one connection element (24) are arranged lying on top of one another in a covering area (50), as seen in a direction perpendicular to the printed circuit board, and are welded to one another in the covering area (50), and the at least one metal web (34) or the at least one connection element (24) makes electrical contact with the at least one contact area (13a) by means of an electrically conductive material (42) applied to the at least one contact area (13a).