Flexible Foil Connecting Element for Motor Vehicle Control Modules

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Solution Overview

Problem

Existing motor vehicle control modules face challenges in complex production and connection of individual pressed screens, which require multiple process steps and are prone to short circuits due to metallic particles, necessitating a more efficient and space-saving electrical connection solution.

Innovation Solution

A motor vehicle control module utilizing a flexible foil with conductor tracks and contact elements, where the flexible foil provides strain relief and tolerance compensation, and a carrier element enhances stability, with an insulating cover layer preventing short circuits and allowing for compact design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stamped grids are used for electrical connection, then electrical connection is achieved, but production becomes complex and space-consuming

Engineering Contradiction:

Improveproduction complexityVSAvoidconnection structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces traditional stamped grids with a flexible foil that has conductor tracks printed or deposited on it. This flexible foil can be bent and adapted to different geometries, simplifying the manufacturing process while reducing the overall complexity of the connection structure. The flexible nature allows for easier integration into the control module housing.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention changes the fundamental parameter of the connection structure from rigid stamped grids to a flexible foil with conductor tracks. This parameter change enables simpler production processes and reduces the number of manufacturing steps required, directly addressing the production complexity issue.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If stamped grids are used for electrical connection, then electrical connection is established, but risk of short circuits from metallic particles increases

Engineering Contradiction:

Improveshort circuit riskVSAvoidproduction process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The flexible foil acts as a barrier that prevents metallic particles from causing short circuits. The conductor tracks are embedded within or on the surface of the flexible material, providing protection against particle contamination while maintaining electrical connectivity. This significantly reduces the risk of short circuits compared to exposed stamped grids.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible foil with conductor tracks represents a composite structure that combines insulating flexible material with conductive traces. This composite approach provides both electrical connection functionality and protection against short circuits from metallic particles, improving reliability without complicating production.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If conventional rigid connections are used, then structural stability is achieved, but tolerance compensation is insufficient

Engineering Contradiction:

Improvetolerance compensationVSAvoidconnection stability

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The flexible foil introduces dynamic capability to the connection structure. It can bend and deform to accommodate manufacturing tolerances and thermal expansion differences between components. This dynamic flexibility enables effective tolerance compensation while maintaining stable electrical connections, resolving the contradiction between rigidity and tolerance adaptation.

Inventive Principle:

Principle #15Dynamics

4Reliability

If more space is allocated for electrical connections, then connection reliability is improved, but overall module size increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmodule size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The flexible foil with conductor tracks allows electrical connections to be arranged in three-dimensional space rather than requiring flat, space-consuming layouts. The foil can be routed through available spaces and bent to connect components in ways that save volume while maintaining reliable electrical connections, thus reducing overall module size without compromising connection reliability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP2875552B1Motor vehicle control module having a connecting element and vehicle having such a motor vehicle control module

Publication Date: 2019.10.09 ZF CV SYST HANNOVER GMBH

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AI summary

The invention relates to a connecting element (2) for producing an electric connection between a connector and an electronic unit, in particular motor vehicle control electronics. To this end, the connecting element (2) has a flexible film (4) having at least one conductor track. In order to produce at least one electric connection between the flexible film (4) and the electronic unit, at least one bonding surface (6) is arranged on the flexible film (4). Furthermore, at least one contact element (8) is fixed to the flexible film (4), wherein the contact element (8) or the contact elements (8) is/are electrically connected to the bonding surface (6) via at least one conductor track. The invention further relates to a motor vehicle control module having such a connecting element (2), to a motor vehicle having such a motor vehicle control module or such a connecting element (2), and to a method for producing an electric connection between a connector and the electronic unit.