Integrally Molded Metal Housing Case for Vehicle Electronic Control Device
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Solution Overview
Problem
The existing electronic control devices face challenges in production efficiency and cost due to the additional filling step of resin composition, thermal expansion coefficient differences leading to peeling stress, and water accumulation issues at the bonding interface, necessitating a solution for a reliable and cost-effective design.
Innovation Solution
An electronic control device with a housing case integrally molded with a heat sink, electromagnetic shield, and vehicle mounting fixture, using a metal material for enhanced thermal conductivity and rigidity, and a sealing resin that covers the outer periphery to improve contact reliability and reduce component count, along with a method of fixing the connector unit assembly to the housing case before attaching it to the control substrate to minimize peeling stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin composition is filled along the outer peripheral portion of the bonding interface between the metal base and the sealing resin, then waterproof reliability is improved, but production efficiency deteriorates due to additional filling step and cost increases due to use of resin composition
Solution Approach 1:
The housing case is integrally molded with the heat sink, electromagnetic shield, and mounting fixture as a single metal component, eliminating the need for separate filling operations at multiple bonding interfaces. This integration maintains waterproof reliability while simplifying the manufacturing process and improving production efficiency.
Solution Approach 2:
The metal housing case serves multiple functions simultaneously: it provides structural support, acts as a heat sink for thermal management, functions as an electromagnetic shield, and includes integrated mounting fixtures. This multi-functionality eliminates the need for additional components and filling operations, resolving the contradiction between reliability and productivity.
2Reliability
If resin composition is filled along the outer peripheral portion of the bonding interface, then cost increases due to use of additional resin composition
Solution Approach 1:
By integrating the heat sink, electromagnetic shield, and mounting fixture into a single metal housing case, the design eliminates multiple bonding interfaces that would require resin composition filling. This reduces material costs and simplifies manufacturing while maintaining bonding interface reliability.
Solution Approach 2:
The multi-functional metal housing case consolidates multiple components into one, eliminating the need for additional resin filling operations and associated materials. This approach maintains reliability while reducing manufacturing cost through material elimination and process simplification.
3Reliability
If control substrate is sealed with resin, then heat resistance and vibration resistance are improved, but peeling stress occurs due to difference in thermal expansion coefficient between metal base and sealing resin
Solution Approach 1:
The patent changes the material parameter by using a metal housing case instead of a resin-sealed structure. The metal housing provides inherent heat resistance and vibration resistance without the peeling stress problem, as metal materials have comparable thermal expansion coefficients and maintain structural integrity under thermal and vibrational loads.
Solution Approach 2:
The integrally molded metal housing case combines multiple functions (structural support, heat dissipation, electromagnetic shielding) in a single material system, eliminating the need for resin sealing and avoiding the thermal expansion mismatch between dissimilar materials that causes peeling stress.
4Area of stationary object
If engine compartment is downsized to achieve enhanced comfortability, then cabin space is increased, but layout difficulty increases and weight increases due to arrangement of large number of electronic control devices and wire harnesses
Solution Approach 1:
The patent integrates multiple functions (mounting, heat dissipation, electromagnetic shielding) into a single housing case structure, reducing the number of separate components and simplifying the overall layout in the engine compartment. This integration reduces layout complexity while maintaining or improving cabin space.
5Volume of stationary object
If wire harness is shortened to install engine control device closer to the engine, then installation space is reduced, but heat resistance and vibration resistance requirements increase
Solution Approach 1:
The patent changes the material parameter by using a metal housing case with inherent heat resistance and vibration resistance properties. This allows the control device to be installed closer to the engine in a shortened wire harness configuration without compromising reliability, as the metal housing provides the necessary environmental protection.
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
This configuration enhances heat dissipation, electromagnetic shielding, and waterproof reliability while reducing production costs and complexity, achieving a highly reliable and cost-effective electronic control device.
Implementation Method 1
using a metal material for enhanced thermal conductivity
Implementation Method 2
housing case integrally molded with a heat sink, electromagnetic shield
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(h)
Figure 3
AI summary
Providing a highly reliable electronic control device capable of achieving both low cost and productivity. An electronic control device including an electronic component, a control substrate on which the electronic component is mounted, and a sealing resin that seals the control substrate, the electronic control device being installed outside the vehicle cabin or in the engine compartment, the electronic control device further including a housing case that fixes the control substrate, and an outer periphery of the housing case being covered with a sealing resin.