Flexible PCB Valve Coil Module for Automotive Braking ECU
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Solution Overview
Problem
Current electronic control units for motor vehicle braking systems fail to adequately address space, weight, and cost constraints while ensuring robustness against environmental influences and modularization requirements.
Innovation Solution
An electronic control unit design featuring a valve coil module with holders arranged on an annular cover surface, connected to a carrier plate and circuit board, allowing for force-fitting or form-fitting attachment, and incorporating elastic elements for resilience, which reduces space and weight requirements and facilitates modularization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid mechanical connection is used between the carrier plate and valve coils, then the structural stability is improved, but the ability to address manufacturing tolerances and thermal expansion deteriorates
Solution Approach 1:
The patent employs flexible printed circuit boards (PCBs) instead of rigid mechanical connections. The flexible PCB allows for elastic deformation to accommodate manufacturing tolerances and thermal expansion while maintaining electrical and mechanical connections. This resolves the contradiction by providing both structural stability through the PCB framework and adaptability through its flexible nature.
Solution Approach 2:
The patent utilizes the change in physical state of materials under thermal conditions and mechanical stress. The flexible PCB changes its dimensional parameters (length, width) in response to thermal expansion and manufacturing variations, allowing the system to adapt without compromising structural integrity. This parameter change enables the system to maintain stability while accommodating tolerances.
2Reliability
If separate support plates and complex fastening mechanisms are used for valve coils, then the reliability of connection is improved, but the device complexity and space requirements deteriorate
Solution Approach 1:
The patent merges the support function, electrical connection function, and mechanical fastening function into a single integrated flexible PCB structure. The flexible PCB simultaneously provides mechanical support for valve coils, electrical connections through conductive traces, and secure attachment through adhesive layers and structural integration. This eliminates the need for separate support plates and complex fastening mechanisms while maintaining connection reliability.
Solution Approach 2:
The flexible PCB serves multiple functions: it acts as a structural support element, an electrical circuit board, a thermal management component, and a mechanical fastening element. This multi-functionality reduces the overall number of components needed in the braking system while ensuring reliable connections for valve coils.
3Reliability
If integrated systems with increased functional assemblies are used, then the safety and robustness are improved, but the space requirements and weight deteriorate
Solution Approach 1:
The flexible PCB enables a thinner, lighter construction compared to rigid multi-layer assemblies. By using flexible materials and eliminating the need for heavy metal support structures and complex fastening hardware, the overall weight of the control unit is reduced while maintaining robustness through the flexible connection system's ability to withstand vibrations and thermal cycles.
Solution Approach 2:
The patent combines multiple functional assemblies (support structure, electrical connections, signal processing, and control electronics) into a single integrated flexible PCB-based system. This integration eliminates the weight of separate components and their interconnections while enhancing robustness through unified design that better withstands environmental influences.
4Ease of manufacture
If modularization is implemented to reduce space and weight, then the ease of manufacture and cost are improved, but the connection reliability under vibration deteriorates
Solution Approach 1:
The flexible PCB provides inherent vibration resistance through its elastic properties. The flexible material can absorb and dissipate vibrational energy without creating rigid stress concentrations that would lead to connection failures. This allows modularized assemblies to maintain high connection reliability under vibration while benefiting from the ease of manufacture and cost advantages of modular design.
Solution Approach 2:
The patent employs dynamic connection solutions where the flexible PCB can adapt its shape and stress distribution in response to vibrational forces. This dynamic behavior allows the modularized system to maintain reliable connections during vehicle operation despite the reduced mass and simplified construction enabled by modularization.
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 design reduces the structural volume of valve coil modules, enhances magnetic force efficiency, and supports modular assembly, achieving cost savings and improved robustness against environmental factors.
Implementation Method 1
a solenoid coil (11), which, when electrified, acts on a corresponding valve of the hydraulic unit in order to open or close the same
Implementation Method 2
at least one elastic element (3), which compensates for mounting position deviations
Data Source
Figure 1a~1b
Figure 2
Figure 3a
AI summary
The invention describes an electronic control unit (12) for connection with a hydraulic unit in a motor vehicle braking system, wherein at least one valve coil module (1) is connected to at least one carrier plate (13) and/or circuit board by means of a holder (2) in addition to the coil connection contact (4) in a force-fit and/or form-fit manner. According to the invention, the holder (2) is arranged on an annular cover surface of a coil body (10) carrying a cylindrical coil (11), wherein an inner diameter of the cover surface is formed by a valve dome receiving opening (8).