ECU Coupling Assembly With Rotating Guide Tracks for Heat Transfer
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Solution Overview
Problem
Existing electric coupling systems for electronic control units (ECUs) in vehicles face issues with damage to thermal contact surfaces during assembly, inadequate heat dissipation, and unreliable electrical and mechanical connections, leading to limited functionality and safety concerns.
Innovation Solution
The electric coupling system features a guide element and guide track configuration that allows the ECU to be inserted and rotated relative to the receiving unit, enabling planar contact and improved frictional connections, which reduces surface damage and enhances thermal and electrical conductivity, ensuring reliable mechanical, thermal, and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal contact surfaces are slid over each other in parallel during assembly, then the ECU can be connected to the receiving unit, but damage to thermal contact surfaces occurs resulting in poorer heat dissipation
Solution Approach 1:
Instead of sliding thermal contact surfaces parallel to each other, the patent inverts the approach by using guide elements and guide tracks that guide the ECU housing into the receiving housing along a path where the thermal contact surfaces approach each other perpendicularly or at an optimized angle, preventing scraping damage while ensuring proper alignment and contact.
2Ease of manufacture
If thermal contact surfaces rest on each other without sufficient pressing force, then assembly is simple, but heat transfer from ECU to receiving unit is limited
Solution Approach 1:
The guide elements and guide tracks are pre-configured to automatically apply pressing force to the thermal contact surfaces as the ECU housing is inserted into the receiving housing. This preliminary action ensures sufficient contact pressure is established during the assembly process itself, eliminating the need for additional pressing steps while guaranteeing effective heat transfer.
3Ease of operation
If the ECU is inserted directly into the receiving unit without rotation capability, then the connection process is straightforward, but the reliability of electrical and mechanical connections is limited
Solution Approach 1:
The patent introduces dynamic capability to the connection process by allowing the ECU housing to rotate relative to the receiving housing during insertion. The guide elements and guide tracks are designed to accommodate this rotation, enabling the system to transition from a static straight-insertion process to a dynamic multi-degree-of-freedom insertion process that achieves more reliable connections.
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 configuration prevents damage to thermal contact surfaces, improves heat transfer, and provides a more reliable and stable connection, reducing the risk of detachment and enhancing overall system performance.
Implementation Method 1
The guide element and the guide track are configured to be brought into sliding engagement with each other such that the ECU can be inserted and slide into the receiving housing
Implementation Method 2
a heat sink with a second thermal contact surface for establishing planar contact with the first thermal contact surface
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5c
AI summary
The present disclosure refers to an electric coupling system (1) comprising an ECU (10) with an ECU housing (11) having at least one guide element (12, 13) and a first thermal contact surface (15), and an electric connector (18). The electric coupling system (1) further comprising a receiving unit (20) for coupling with the ECU (10), the receiving unit (20) comprising a receiving housing (21) to accommodate the ECU (10), the receiving housing (21) comprising at least one guide track (22, 23) and a heat sink (24) with a second thermal contact surface (25) for establishing planar contact with the first thermal contact surface (15), and an electric counter connector (28) for mating with the electric connector (18), wherein the guide element (12, 13) and the guide track (22, 23) are configured to be brought into sliding engagement with each other such that the ECU (10) can be inserted and slide into the receiving housing (21), wherein the guide element (12, 13) and the guide track (22, 23) are further configured such that the ECU (10) can be rotated relative to the receiving unit (20) while coupling the ECU (10) with the receiving unit (20).