Electronic Control Device Direct Terminal Connection
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Solution Overview
Problem
Conventional electronic control devices for electric motors in vehicles require a DC bus bar for wire bonding and welding, increasing the number of parts and resulting in higher procurement and capital investment costs.
Innovation Solution
An electronic control device design that eliminates the need for a DC bus bar by using two housings with a first circuit board and terminals that connect directly when the housings are coupled, reducing the number of parts and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a DC bus bar is used for wire bonding and welding, then reliable electrical connections are achieved, but the number of parts increases and manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the DC bus bar component from the system by establishing direct electrical connections between terminal electrodes on opposing circuit boards through conductive holes in the insulating plates. This removes the intermediate connecting member while maintaining electrical connectivity.
Solution Approach 2:
The patent merges the functions of the DC bus bar, terminal connections, and structural support into the circuit board assembly itself. The terminal electrodes on the circuit boards directly establish electrical connections without requiring a separate bus bar component, combining multiple functions into integrated structures.
2Reliability
If a DC bus bar is used for wire bonding and welding, then electrical connections are established, but procurement cost and capital investment expenses increase
Solution Approach 1:
The patent removes the DC bus bar component entirely, eliminating the need for separate procurement and capital investment in bus bar inventory. The electrical connection function is achieved through integrated terminal electrodes and conductive holes in the circuit board assembly.
Solution Approach 2:
The patent uses standard terminal electrodes and conductive hole structures that are already part of the circuit board manufacturing process, replacing the need for expensive, specialized bus bar components. This approach uses readily available, cost-effective manufacturing methods.
3Device complexity
If terminal electrodes are directly connected through conductive holes, then the number of parts is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates conductive holes and terminal electrode positions into the circuit board design and manufacturing process from the outset. The holes are precisely positioned during PCB fabrication, and terminal electrodes are mounted with predetermined positions, ensuring accurate alignment before assembly.
Solution Approach 2:
The conductive holes in the insulating plates serve as intermediaries that precisely align and connect terminal electrodes from opposing circuit boards. The holes provide a fixed, pre-determined pathway that ensures accurate positioning and electrical connection.
Data Source
AI summary
An electronic control device including two housings coupled to each other, a first circuit board disposed in one of the two housings, a first terminal disposed on a side of the other of the two housings, and a second terminal disposed on the first circuit board in an opposed relation to the first terminal, wherein the first terminal and the second terminal are brought into direct connection with each other at a time at which the two housings are coupled to each other.