Modular Car Fan Controller Assembly Without Resin Bonding

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Solution Overview

Problem

Current radiator fan controllers are inefficient due to outdated assembly processes that require resin bonding, leading to high production costs and waste, as well as limited maintenance options, where the entire unit must be replaced if issues arise.

Innovation Solution

A modular car fan controller design that secures electronic components without resin, allowing for easy access and replacement of internal components through a removable top cover and bottom plate, with a water-resistant adjustment device and modular wire harness configuration for flexible sensor attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If resin bonding is used to secure electronic components to the housing, then the assembly is sealed and protected, but the production time increases due to curing requirements and the entire unit must be replaced if components fail

Engineering Contradiction:

Improvesealing protectionVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The controller is divided into separable modules: the housing, circuit board, and wire harness connector are distinct components that can be assembled and disassembled independently. This eliminates the need for resin bonding while maintaining structural integrity and enabling partial replacement of components without replacing the entire unit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wire harness connector and circuit board are extracted as removable components from the housing. This allows these components to be replaced individually without replacing the entire controller, reducing waste and production costs while eliminating the need for time-consuming resin curing processes.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If resin bonding is used to secure electronic components, then the assembly is sealed, but production costs increase and waste is generated when the entire unit must be replaced

Engineering Contradiction:

Improvesealing protectionVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular design enables selective replacement of only the faulty component (wire harness connector or circuit board) while retaining the functional housing and other components. This reduces material waste and production costs by avoiding replacement of the entire controller unit.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If the entire controller unit is replaced when components fail, then reliability is maintained, but production costs increase and waste is generated

Engineering Contradiction:

Improvesystem reliabilityVSAvoidcomponent waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #34Discarding and recovering

4Reliability

If resin bonding is used to secure electronic components, then the assembly is protected, but the assembly process becomes old and inefficient

Engineering Contradiction:

Improveassembly protectionVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS8130505B2Car fan controller

Publication Date: 2012.03.06 SCHURZ JAMES HSU

AI summary

This invention patent is a utility type of car fan controller. The controller has a housing and inside the housing is a circuit. The housing has a top cover forming a cavity and flat bottom plate. The circuit has a circuit board and an adjustment device with other electronic components. The circuit board has a socket connector and a wire harness connector. The top cover has socket connector aligned with socket connector opening. The top cover also has a wire harness connector aligned to wire harness connector socket. The modular practical new type of invention design facilitates faster assembly and more convenient flexible use.