ECU Coupling Assembly With Rotational Thermal Contact
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Solution Overview
Problem
Existing electric coupling systems for ECUs face issues with damage to thermal contact surfaces during parallel sliding, insufficient heat dissipation, and unreliable electrical and mechanical connections, leading to potential detachment and limited functionality.
Innovation Solution
An electric coupling system with a guide element and guide track configuration that allows the ECU to be inserted and rotated relative to the receiving unit, ensuring planar contact and pressing of thermal surfaces without parallel sliding, enhancing thermal, mechanical, and electrical connections through sliding and rotational engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal contact surfaces are slid over each other in parallel during insertion, then the ECU can be connected to the receiving unit, but the thermal contact surfaces are damaged resulting in poorer heat dissipation
Solution Approach 1:
Instead of sliding the thermal contact surfaces parallel to each other during insertion, the patent inverts the approach by using guide elements and guide tracks that allow the ECU to be inserted first, then rotated into the final position. This inversion of the insertion sequence prevents direct sliding contact between the thermal surfaces during the connection process, thereby avoiding damage while maintaining ease of operation.
Solution Approach 2:
The patent segments the connection process into two distinct phases: insertion phase (using guide elements and guide tracks for alignment) and rotation phase (for final thermal contact). This segmentation separates the alignment function from the thermal contact function, allowing each to be optimized independently and preventing damage to thermal surfaces during alignment.
2Device complexity
If thermal contact surfaces rest on each other without sufficient pressure, then the connection is simple, but heat transfer from ECU to receiving unit is limited
Solution Approach 1:
The patent introduces a dynamic element (spring) that automatically applies sufficient pressure to the thermal contact surfaces once the ECU is rotated into position. This dynamic pressure application ensures reliable heat transfer without requiring complex pre-adjusted mechanical pressure systems, maintaining simplicity while improving heat transfer reliability.
3Ease of operation
If the ECU is inserted using parallel sliding of thermal contact surfaces, then the connection process is simple, but the electrical and mechanical connections become unreliable leading to detachment
Solution Approach 1:
The patent inverts the traditional insertion sequence by separating alignment (via guide elements and tracks) from final positioning (via rotation). This inversion allows the electrical and mechanical connections to be established in a controlled rotational motion rather than forced parallel sliding, significantly improving connection reliability while maintaining ease of operation.
Solution Approach 2:
The patent adds a rotational dimension to the insertion process. Instead of purely linear parallel sliding, the ECU is first inserted linearly through guide elements and tracks, then rotated into the final position. This dimensional change enables reliable establishment of electrical and mechanical connections without compromising the simplicity of the insertion process.
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 ensures reliable electrical and mechanical connections, reducing the risk of detachment and enhancing overall system stability and 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
Implementation Method 3
a heat sink with a second thermal contact surface for establishing planar contact with the first thermal contact surface
Data Source
AI summary
Disclosed is an electric coupling system including an electronic control unit (ECU). The ECU includes an ECU housing having at least one guide element and a first thermal contact surface. The ECU includes an electric connector. The electric coupling system further includes a receiving unit for coupling with the ECU. The receiving unit includes a receiving housing to accommodate the ECU at least partially, the receiving housing including at least one guide track and a heat sink with a second thermal contact surface for establishing planar contact with the first thermal contact surface. The receiving unit further includes an electric counter connector for mating with the electric connector.