Flexible Conductor Foil Connection for Encapsulated Electronics
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Solution Overview
Problem
Existing electrical connection arrangements for motor vehicle transmission control units are prone to vibration, short circuits, and environmental damage from transmission fluid, particularly in encapsulated electronic modules with conventional contact methods.
Innovation Solution
A robust, flexible electrical connection arrangement featuring a printed circuit board with encapsulated electronics and a flexible conductor foil, where contact ends are supported on a protective compound shoulder, providing comprehensive protection and reliable connection through soldered or welded contacts, and incorporating features like recesses and polymer coatings for enhanced stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional contact methods are used in encapsulated electronic modules, then assembly is simpler, but the connection is prone to vibration and short circuits
Solution Approach 1:
The contact plate is segmented into a body portion and a contact end portion with an intermediate section, allowing each segment to perform its specific function optimally while contributing to overall reliability
Solution Approach 2:
The contact plate utilizes composite construction with different sections having different properties - the body portion provides structural support while the contact end portion is optimized for electrical contact and vibration resistance
2Object-affected harmful factors
If the electronic circuit is encapsulated with protective compound, then protection against environmental influences is improved, but the contact areas are exposed to conductive chips and deposits
Solution Approach 1:
The contact end portion is designed to extend beyond the encapsulation before final assembly, allowing it to make contact with the conductor foil while the protective compound is still being applied or immediately thereafter, ensuring contact is established in a protected manner
Solution Approach 2:
The contact end portion acts as an intermediary element that extends from the encapsulated electronic circuit to the external conductor foil, providing a protected pathway for electrical contact that is shielded from conductive chips and deposits by the protective compound
3Strength
If rigid contact plates are used, then mechanical strength is improved, but vibration and thermal expansion cause connection failures
Solution Approach 1:
The contact end portion is designed with dynamic characteristics that allow it to flex and adapt to vibrations and thermal expansion, while the body portion maintains rigid structural support, creating a system that combines strength with vibration resistance
Solution Approach 2:
The contact plate exhibits parameter changes in its intermediate section, transitioning from the rigid body portion to a more flexible contact end portion, allowing adaptation to environmental conditions while maintaining structural integrity
4Productivity
If automated assembly is implemented, then productivity is improved, but assembly precision requirements increase
Solution Approach 1:
The contact plate design incorporates universal features such as standardized mounting surfaces and contact geometries that can be consistently manufactured and assembled automatically, reducing precision requirements while maintaining connection reliability
Solution Approach 2:
The contact plate has different local qualities - the body portion provides robust mechanical mounting with standardized features for automated assembly, while the contact end portion is precisely formed for reliable electrical contact, allowing automated assembly at critical interfaces
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention proposes an electrical connection arrangement (10) which has an electronics module (122), comprising an electronic circuit (16) which is arranged on a mounting area (17) of a printed circuit board element (14), and a flexible conductor foil (36) with conductor tracks (42) accommodated between a base layer (38) and a covering layer (40), wherein the electronic circuit is at least partially covered by a protective mass (18) in order to provide protection against environmental influences. The electronics module has a plurality of contact plates (20) which are arranged next to one another and which each have a contact end (26) which projects away from a flank (24) of the electronics module, wherein the contact ends of the contact plate are each electrically conductively connected to a conductor track of the conductor foil. The connection arrangement is distinguished in that a projection (28) is formed by the protective mass (18) at the flank (24) of the electronics module (12), the contact ends (26) of the contact plates (20) and at least one subregion (44) of the conductor foil being supported on the said projection. This results in a robust and compact connection arrangement.