Rotating PCB Assembly for Sealed ECU Housing
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Solution Overview
Problem
Manufacturing sealed electronic control modules with right-angle connectors is challenging and expensive due to multiple interfaces requiring sealing, and conventional sealing methods have shortcomings such as potential leak paths and high costs.
Innovation Solution
A method of assembling an electronic control unit with a rotating printed circuit board (PCB) using a terminal carrier with right-angle terminal pins, where the terminal carrier interlocks with the housing to eliminate leak paths and reduce manufacturing costs by integrating connector geometry into the housing, allowing for robust assembly and precise control over pin location and insertion depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods (dispensed seals, gaskets, potting, or bonding) are used to seal connectors to electronic module housings, then sealing protection is achieved, but manufacturing cost increases and potential leak paths remain
Solution Approach 1:
The connector housing and electronic module housing are merged into a single integrated housing structure. The connector is formed as an integral part of the housing, eliminating the need for separate sealing components such as gaskets, dispensed seals, potting compounds, or bonding materials. This integration eliminates potential leak paths at the connector-housing interface while reducing manufacturing complexity and cost.
2Reliability
If multiple sealing interfaces are created to seal connectors to electronic module housings, then sealing protection is achieved, but device complexity increases
Solution Approach 1:
The connector housing and electronic module housing are merged into a single integrated housing structure. The connector is formed as an integral part of the housing, eliminating the need for separate sealing components such as gaskets, dispensed seals, potting compounds, or bonding materials. This integration eliminates potential leak paths at the connector-housing interface while reducing manufacturing complexity and cost.
3Adaptability or versatility
If right angle connectors are used in sealed electronic modules, then electrical connection functionality is achieved, but sealing difficulty increases due to multiple interfaces
Solution Approach 1:
The connector housing and electronic module housing are merged into a single integrated housing structure. The connector is formed as an integral part of the housing, eliminating the need for separate sealing components such as gaskets, dispensed seals, potting compounds, or bonding materials. This integration eliminates potential leak paths at the connector-housing interface while reducing manufacturing complexity and cost.
Data Source
AI summary
A method of assembling an electronic control unit comprises assembling a printed circuit board (PCB) substrate with a terminal carrier holding a plurality of terminal pins comprising a right angle bend into a housing using a rotational motion. The terminal carrier generally extends perpendicularly from the PCB substrate. A first end of each of the plurality of terminal pins is inserted into the PCB substrate and a second end of each of the plurality of terminal pins extends through the terminal carrier. The second ends of the plurality of terminal pins generally extend into one or more connector openings in one of four sides of the housing and the terminal carrier interlocks with the housing to hold the PCB substrate with the terminal carrier and the plurality of terminal pins in place.