Sealed ECU Connector Assembly for Smear-Free Vertical Sealing
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Solution Overview
Problem
Existing electronic module designs face issues with excessive smearing of dispensed sealant during assembly, leading to seal failures, and require separate curing processes or reorientation of parts, which are inefficient and costly.
Innovation Solution
A sealed electronic control unit (ECU) assembly featuring an upper housing with angled ramp features and a connector assembly that interlock to minimize sealant smearing, allowing vertical assembly without additional curing or reorientation, using a continuous sealant bead to form a robust environmental seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connector-housing interfaces are used with dispensed sealant, then sealing is achieved, but excessive smearing of sealant occurs during assembly leading to seal failure
Solution Approach 1:
The sealant is pre-dispensed into the sealant channel formed by the ramp features before assembly occurs. This preliminary placement of the sealant in a controlled position prevents smearing during the assembly process, as the sealant is already positioned where it needs to be compressed into the seal interface.
Solution Approach 2:
The ramp features create a curved or angled sealant channel that guides and contains the sealant in a controlled path. This curved geometry prevents the sealant from spreading laterally during assembly, maintaining precise control over sealant placement while ensuring proper compression at the seal interface.
2Reliability
If separate curing processes or components are added to compress the sealant, then seal quality improves, but assembly complexity and cost increase
Solution Approach 1:
The sealing function is merged into the standard assembly process itself. The act of assembling the connector into the housing simultaneously compresses the pre-dispensed sealant through the ramp features, eliminating the need for separate curing processes or additional compression components. The assembly operation performs dual functions: mechanical connection and seal formation.
Solution Approach 2:
The assembly process self-compresses the sealant through the mechanical interaction of the ramp features during normal connector insertion. The structure is designed so that the natural forces applied during assembly (insertion force, interlocking of features) are sufficient to compress the sealant into the sealing interface without requiring external curing equipment or additional compression mechanisms.
3Reliability
If reorientation of parts is required during assembly, then proper sealant compression is achieved, but assembly time and productivity decrease
Solution Approach 1:
The vertical assembly motion performs multiple functions simultaneously: it positions the connector, engages the interlocking features, and compresses the sealant through the ramp features. This single universal motion eliminates the need for separate reorientation steps, maintaining both seal quality and assembly speed.
Solution Approach 2:
The sealant is pre-positioned in the channel and the ramp features are pre-configured to guide compression during vertical insertion. This preliminary preparation ensures that the single vertical assembly motion is sufficient to achieve proper seal compression without requiring subsequent reorientation or additional compression steps.
Data Source
AI summary
An apparatus includes a upper housing and a connector and printed circuit board assembly. The upper housing comprises three sides extending perpendicularly from a fourth side, where the four sides of the housing define a rectilinear volume and a connector opening, and the connector opening comprises one or more first ramp features configured to hold a sealant. The connector and printed circuit board subassembly comprises a connector assembly holding a plurality of terminal pins and attached to a printed circuit board substrate. The connector assembly extends perpendicularly from the printed circuit board substrate. Each of the plurality of terminal pins comprises a right angle bend. A first end of each of the plurality of terminal pins is inserted into the printed circuit board substrate. A second end of each of the plurality of terminal pins extend through the connector assembly. The connector assembly comprises one or more second ramp features configured to mate with the one or more first ramp features of the upper housing. The upper housing is configured to (i) allow assembling of the connector and printed circuit board subassembly into the upper housing using a vertical motion and (ii) interlock with the connector assembly to hold the printed circuit board substrate with the connector assembly and the plurality terminal pins in place within the housing.