Flexible Control Unit with Injection Moulded Layer
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Solution Overview
Problem
Modern vehicles face challenges in accommodating numerous electronic control units due to space constraints, inflexible design, and weight issues, which complicates their integration and functionality.
Innovation Solution
A control unit with a pliable component-carrying member and an injection moulded layer that allows for flexible shaping and embedding of electronic components, providing a lightweight, robust, and versatile structure that can be adapted to various forms and applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rigid control units with printed circuit boards are used, then structural stability is improved, but adaptability to different spaces and shapes deteriorates
Solution Approach 1:
The control unit employs a flexible circuit board instead of a rigid printed circuit board, enabling the structure to be dynamically adapted to different spatial configurations and shapes while maintaining electrical connectivity and structural integrity
Solution Approach 2:
The control unit utilizes a flexible circuit board that can be bent and shaped to fit various spaces within the vehicle, replacing traditional rigid PCB structures with flexible thin-film technology that maintains electrical functionality while adapting to complex geometries
2Adaptability or versatility
If more control units are added to vehicles, then functionality is improved, but space occupation deteriorates
Solution Approach 1:
The control unit integrates multiple electronic components and control functions into a single compact unit, combining what would traditionally require separate control units into one unified device that occupies less space while providing enhanced functionality
Solution Approach 2:
The control unit is designed with multi-functional capabilities, allowing a single unit to perform multiple control functions that would traditionally require separate dedicated control units, thereby reducing the total number of units and overall space occupation in the vehicle
3Shape
If control units are hidden behind trim panels, then aesthetic appearance is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The control unit is designed as a modular, self-contained component that can be independently accessed and maintained, with segmented construction that allows for easy removal and installation without requiring disassembly of surrounding trim panels or interior components
Data Source
AI summary
A control unit (10) for an apparatus (12), the control unit (10) comprising a component-carrying member (14; 114; 18; 118) provided with at least one electronic component (30, 32, 34, 36, 38; 60, 62; 74, 78) configured to provide a function of the apparatus (12); wherein the component-carrying member is formed of a material that is pliable at least during assembly of the control unit (10). The control unit is provided with an injection moulded layer (22; 22′) encapsulating at least a part of the or each electronic component (30, 32, 34, 36, 38; 60, 62; 74, 78).