Electronic Control Device Terminal Design for Reliable Compact Connections
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Solution Overview
Problem
Conventional electronic control devices face challenges in achieving reliable connections between terminals while maintaining a compact size, as the use of tuning fork terminals can lead to unstable connections and increased device size when reinforced.
Innovation Solution
The electronic control device employs a design where a circuit board is housed in a cabinet with bonded cabinet members, featuring a first terminal on one cabinet member and a second terminal on the board with bending sections and connection sections that allow for press-fitting and secure electrical bonding, eliminating the need for tuning fork terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a tuning fork terminal is used to connect terminals from mutually opposite directions, then the device size can be reduced, but the connection reliability is reduced due to unstable connection under load
Solution Approach 1:
The terminal is divided into multiple functional sections: a bottom surface section for electrical bonding to the circuit board, a pair of bending sections that stand up and bend toward each other, and a pair of connection sections at the tips. This segmentation allows each part to perform its specific function optimally while maintaining overall compactness and connection reliability.
Solution Approach 2:
The bending sections are designed to be flexible and deformable, allowing them to bend toward each other during press-fitting to create a reliable mechanical and electrical connection. The dynamic flexibility of these sections enables the terminal to accommodate assembly variations and maintain stable contact under load without requiring excessive thickness or reinforcement.
2Reliability
If the tuning fork terminal is made thicker or reinforced with a bus bar to endure load, then the connection reliability is increased, but the device size increases
Solution Approach 1:
Instead of increasing terminal thickness statically, the bending sections are designed with appropriate flexibility to dynamically adapt during connection. The sections bend toward each other under press-fitting force, creating a reliable connection without requiring excessive material thickness or additional reinforcement structures.
Solution Approach 2:
The terminal integrates multiple functions into a single component: electrical bonding to the circuit board, mechanical support, and electrical connection to the first terminal. This merging eliminates the need for separate reinforcement structures like bus bars while maintaining connection reliability through the integrated bending and connection sections.
3Reliability
If wire bonding or welding is used to connect terminals, then the connection reliability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The terminal structure performs its own connection function through the press-fitting of the first terminal into the space between the bending sections. The bending sections automatically deform and secure the connection without requiring external wire bonding or welding processes, simplifying manufacturing while maintaining reliability.
Solution Approach 2:
The invention replaces complex electrical connection methods (wire bonding, welding) with a simpler mechanical press-fitting system. The bending sections provide mechanical clamping force that secures the first terminal, eliminating the need for thermal or electrical joining processes and reducing manufacturing 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 configuration ensures reliable connections between terminals while allowing for a compact device size, reducing the need for additional reinforcement and simplifying manufacturing, thus enhancing connection reliability and reducing device complexity.
Implementation Method 1
a bottom surface section fixed to a land section of the circuit board through an electrical bonding
Implementation Method 2
a pair of bending sections which stand up from both end sides of the bottom surface section and bent in directions mutually approaching to each other
Implementation Method 3
a tip side of the first terminal being press fitted into a space between the pair of connection sections from a stand up direction side of the bending sections to be connected to the pair of connection sections
Data Source
AI summary
An electronic control unit includes a casing and a cover which are mutually bonded. A drive circuit board which drives a motor unit is fixed to the cover and, on the other hand, a control circuit board which controls the drive circuit board is fixed to the casing. An electrical connector which supplies an electric power to each board and a motor unit is attached on an opening section of the casing. First power supply terminals of this electrical connector and the motor unit and second power supply terminals of the drive circuit board are directly electrically connected by a bonding of both of casing and the cover.