Headerless Harness Connector Direct ECU Housing Mount
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Solution Overview
Problem
Existing electrical connections for electronics devices, such as Ethernet connections to engine control units (ECUs), are not optimal in terms of cost and performance due to the use of headers that require additional fasteners and result in longer wire lengths.
Innovation Solution
A harness connector is directly attached to the ECU housing, eliminating the need for a header, with a base member and seal members providing a secure, sealed connection to the printed circuit board (PCB) through apertures and fasteners, and featuring compliant press-fit or female connector members for reduced wire length and improved connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a header with fasteners is used to connect the harness connector to the housing, then the connection is secure and reliable, but the manufacturing cost increases and wire length increases
Solution Approach 1:
The patent removes the header component entirely from the connection assembly. The harness connector is designed to attach directly to the housing without requiring a separate header, thereby eliminating unnecessary parts and simplifying the overall structure while maintaining connection reliability through direct mounting features.
Solution Approach 2:
The patent combines the harness connector mounting function directly with the housing structure. The housing incorporates integrated mounting features that allow the harness connector to be attached directly, merging what were previously separate components (header and housing) into a unified structure that reduces complexity and cost.
2Strength
If a header is used to connect the harness connector to the housing, then the connection is secure, but the manufacturing cost increases
Solution Approach 1:
The patent eliminates the header component and its associated fasteners, removing unnecessary manufacturing steps and material costs. The harness connector attaches directly to the housing using integrated mounting features, significantly reducing assembly complexity and manufacturing cost while maintaining adequate connection strength.
Solution Approach 2:
The housing is designed with multi-functional features that serve both structural and mounting purposes. The housing incorporates integrated mounting features that allow direct attachment of the harness connector, eliminating the need for separate headers and fasteners, thereby reducing manufacturing cost and simplifying the supply chain.
3Reliability
If a header is used in the connection assembly, then the connection is secure, but the wire length increases
Solution Approach 1:
By removing the header component from the connection path, the patent shortens the electrical connection path between the harness connector and the PCB. The direct attachment of the harness connector to the housing eliminates the additional wire length that would be required to reach through or around a header structure.
Data Source
AI summary
A harness connector for an electronics device is disclosed, the electronics device having a housing and a printed circuit board disposed in the housing, and the housing including an opening exposing electrical contacts of the printed circuit board. The harness connector includes a base member with a plurality of apertures defined therein, the base member directly attached to the housing and disposed over the opening, and a plurality electrical contacts electrically connected to the electrical contacts of the printed circuit board.