Flexible PCB Housing Assembly for Automotive Electrical Connections
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Solution Overview
Problem
Current electrical connection solutions for electronic components in motor vehicles are bulky, expensive, and heavy, making them inefficient for withstanding environmental stresses such as heat, cold, and rain.
Innovation Solution
An electronic box assembly featuring a printed circuit board with a rigid main part and a flexible periphery, where the flexible part extends between cylindrical walls of the upper and lower housing elements, providing electrical connection pads that are pinched between planar contact surfaces to enhance contact and reduce bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical harnesses and connectors are used to connect electronic control boards and electrical devices, then reliable electrical connection is achieved, but the assembly becomes bulky, expensive, and heavy
Solution Approach 1:
The patent merges the electrical connection function directly into the housing structure by integrating conductive contact surfaces into the cylindrical walls of the housing elements. This eliminates the need for separate electrical harnesses and connectors, achieving reliable electrical connection while significantly reducing weight and complexity.
Solution Approach 2:
The housing elements serve multiple functions: they provide mechanical protection, structural support, and electrical connection. The cylindrical walls with conductive contact surfaces act as both structural components and electrical contacts, eliminating the need for dedicated connector components.
2Reliability
If traditional electrical harnesses and connectors are used, then electrical connection is established, but the assembly cost increases
Solution Approach 1:
The electrical connection function is merged into the housing manufacturing process. The conductive contact surfaces are integrated into the housing elements, allowing electrical connections to be established during the housing assembly process rather than requiring separate connector installation steps, thereby reducing manufacturing cost.
Solution Approach 2:
The housing elements perform multiple functions including mechanical protection, structural support, and electrical connection. This multi-functionality reduces the total component count and assembly steps, leading to lower manufacturing costs.
3Reliability
If traditional electrical harnesses and connectors are used, then electrical connection is achieved, but the assembly size and bulkiness increase
Solution Approach 1:
The electrical connection components are merged into the housing structure itself. The conductive contact surfaces are formed as integral parts of the cylindrical housing walls, eliminating the need for separate harnesses and connectors, thereby significantly reducing assembly volume.
4Reliability
If the flexible part is pinched between cylindrical walls to enhance contact, then electrical contact reliability is improved, but the flexible part may be damaged
Solution Approach 1:
The patent changes the physical parameters of the flexible part, specifically its thickness and material properties, to optimize the balance between contact pressure and damage resistance. The flexible part is designed with appropriate mechanical properties to withstand the pinching force while maintaining reliable electrical contact.
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
The solution provides a compact, efficient, and reliable electrical connection that withstands environmental stresses, reducing the weight and cost of the connection while maintaining effective electrical contact.
Implementation Method 1
sliding the first cylindrical wall into a lower housing element and against the second cylindrical wall of the lower housing element so as to bend the flexible part vertically
Implementation Method 2
inserting the first cylindrical wall into the lower housing element and against the second cylindrical wall of the lower housing element so as to pinch the flexible part between the first and the second cylindrical walls
Data Source
Figure 1
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AI summary
An electronic housing assembly (10) includes a printed circuit board (26) comprising a rigid main part (96) having at least one face containing an electronic component and comprising at least one flexible part (98) arranged around the periphery of the rigid part (96), the flexible part (98) comprising at least one electrical connection pad (108); an upper housing element (12) comprising a first cylindrical wall (48) which is inserted into a lower housing element (14) comprising a second cylindrical wall (116); the flexible part (98) extending between the first and second cylindrical walls (48, 116), the electrical connection pad (108) of the flexible part (98) being in electrical contact with an electrical contact surface which is arranged on the outer face (114) of the first cylindrical wall (48) or on the inner face (118) of the second cylindrical wall (116).