Electronic Control Unit Circuit Contact Reinforcement
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Solution Overview
Problem
Circuits in electronic control units with small sheet metal thickness are prone to deformation when contact pins are pressed into contact holes, leading to inadequate mechanical and electrical connections.
Innovation Solution
The use of an additional electrically conductive support washer with a support disk that covers the contact area, arranged coaxially with the conductor track contact hole, to stiffen the contact area and prevent deformation, while enhancing the contact surface and connection robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conductor tracks are made with small sheet metal thickness to enable flexible design and bending, then adaptability and ease of shaping are improved, but mechanical strength and resistance to deformation during assembly deteriorate
Solution Approach 1:
The support structure is segmented into individual support elements (such as adhesive tabs or reinforcement pieces) that are applied selectively to specific contact areas rather than reinforcing the entire conductor track. This allows the conductor track to remain thin and flexible overall while providing localized reinforcement where mechanical strength is needed during assembly.
Solution Approach 2:
The reinforcement is applied locally only to the contact areas where components need to be mounted, rather than uniformly across the entire conductor track. This maintains the flexible, thin-profile characteristics of the conductor track in non-critical areas while providing enhanced mechanical strength and deformation resistance precisely where contact pins are pressed in.
2Volume of stationary object
If conductor tracks are made with small sheet metal thickness to reduce space and weight, then volume and weight are reduced, but manufacturing precision and assembly reliability deteriorate due to deformation
Solution Approach 1:
The contact holes are pre-formed in the conductor track at the correct positions and orientations before the thin conductor track is assembled into the final circuit board. This preliminary formation of contact holes ensures precise positioning and geometry are established while the conductor track is still in a more manageable state, before potential deformation occurs during subsequent assembly steps.
Solution Approach 2:
Support elements (such as adhesive tabs or reinforcement pieces) are applied in advance to the contact areas before components are mounted. This beforehand reinforcement cushions the thin conductor track against deformation during the component pressing and soldering processes, ensuring that the pre-formed contact holes maintain their precise dimensions and positions throughout assembly.
3Strength
If contact areas are reinforced to prevent deformation during component pressing, then mechanical strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The support elements used to reinforce contact areas are simple, inexpensive components (such as adhesive tabs or thin reinforcement pieces) that can be easily applied and discarded if necessary. These disposable-like support elements provide the needed mechanical reinforcement during assembly without requiring complex, permanent structural modifications to the conductor track design.
Solution Approach 2:
Support elements act as intermediary components between the thin conductor track and the components being mounted. These intermediaries (such as adhesive tabs or reinforcement pieces) absorb the mechanical stress and deformation forces during component pressing, protecting the conductor track and contact holes from damage while simplifying the overall assembly process.
Data Source
Figure 1~1a
Figure 2
Figure 3~3a
AI summary
The invention relates to a circuit (1) of an electronic control unit, having a plurality of conductor tracks (2) which are produced in a leadframe design or in a flex film design and at least one conductor track (2) of which has a contact region (4.1) having at least one conductor track contact hole (5.1) for pressing in a contact pin (6) of a connector element (7) or of an electronic component. In order to prevent deformation of the conductor track (2) when pressing the contact pin (6) into the conductor track contact hole (5.1) in the case of a relatively low sheet thickness DLB of the conductor track (2) of 0.8 mm or less, for example, provision is made in this circuit for the contact region (4.1) of the conductor track (2) to be reinforced with an additional supporting plate (9.1), for the supporting plate (9.1) to consist of an electrically conductive metal sheet, for the supporting plate (9.1) to cover the contact region (4) of the conductor track (2), for the supporting plate (9.1) to be provided with a supporting plate contact hole (11.1), for the supporting plate contact hole (11.1) to be arranged coaxially with respect to the conductor track contact hole (5.1), and for the supporting plate (9.1) to be arranged on one side (10) of the conductor track (2) and to be connected to the conductor track (2).