Plastic ECU Cover with Sealed Center Boss Against Deflection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronics control units (ECUs) face issues with cover deflection due to internal pressure buildup, which compromises sealing effectiveness, and existing solutions like vents or cast covers are either unsuitable for sealed units or costly and heavy.
Innovation Solution
A housing cover with a centrally-located post member integrated into a plastic composition, secured to the housing through a through-hole using hot air riveting or heat staking, and sealed with a protrusion and sealant to prevent outward deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cast cover is used to limit cover deflection, then the cover strength is improved, but the manufacturing cost increases and the weight increases
Solution Approach 1:
The invention divides the cover into two parts: a standard plastic cover and a separate reinforcement ring. The reinforcement ring is installed around the through-hole area where deflection occurs, providing localized strengthening without requiring the entire cover to be cast. This segmentation allows the cover to gain strength where needed while maintaining the cost-effectiveness of standard plastic manufacturing for the rest of the cover.
Solution Approach 2:
The invention uses composite construction by combining a plastic cover with a reinforcement ring made of a different material (metal or rigid plastic). This composite structure provides the strength of the reinforcement ring at the critical deflection zone while maintaining the lightweight and cost-effective plastic material for the majority of the cover, thus resolving the contradiction between strength and manufacturing cost.
2Strength
If a cast cover is used to limit cover deflection, then the cover strength is improved, but the weight increases
Solution Approach 1:
The reinforcement is segmented to only cover the critical area around the through-hole where deflection occurs, rather than making the entire cover heavy. This localized reinforcement provides necessary strength while minimizing additional weight compared to a full cast cover.
Solution Approach 2:
The invention applies local quality by concentrating the reinforcement material only where it is most needed - around the through-hole area that experiences the highest stress and deflection. The rest of the cover maintains its original lightweight plastic construction, thus achieving strength improvement without significant weight penalty.
3Strength
If screws and related hardware are used for securing a central portion of the cover, then the cover deflection is limited, but the manufacturing cost increases
Solution Approach 1:
The invention merges the reinforcement function with the cover structure itself by integrating the reinforcement ring as part of the cover assembly. The ring is positioned to work together with the cover and housing to resist deflection, eliminating the need for separate screws and hardware while providing comparable or superior structural support at lower cost.
Solution Approach 2:
The invention extracts the fastening function from the design by removing the need for screws and related hardware. Instead of using separate fastening components, the reinforcement ring provides both structural support and deflection resistance as an integrated element, simplifying the assembly and reducing manufacturing costs.
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 cost-effective, lightweight, and sealed ECU cover that maintains effective sealing under varying pressure conditions without using screws, ensuring structural integrity and thermal conductivity.
Implementation Method 1
Heat and pressure are applied to a distal end portion of the post member so that the post member is formed over a portion of the housing which defines the through-hole and engages with the housing portion
Implementation Method 2
Heat and pressure are applied to a distal end portion of the post member so that the post member is formed over a portion of the housing
Implementation Method 3
A sealant is disposed in the notch and contacts the distal end portion of the protrusion. The sealant forms a seal between the housing and the housing cover
Data Source
Figure 1~5
Figure 2~3
Figure 4~8
AI summary
An electronics device includes a housing (10, 10') having a through-hole (10A) disposed in a central portion of the housing (10, 10'). A printed circuit board (14) is connected to the housing (10, 10'). The printed circuit board (14) includes one or more electronic components disposed thereon. A plastic housing cover (12) is connected to the housing (10, 10') and cover (12)s the printed circuit board (14). The housing cover (12) includes a centrally-located post member (16) integral to the housing (10, 10'). The post member (16) extends through the through-hole (10A) of the housing (10, 10') and engages with the housing (10, 10'). The engagement between the housing (10, 10') and the housing cover (12) prevents outward deflection of the housing cover (12).