Spring-Clip Housing Joint for EMC Shielding and Gap Tolerance
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Solution Overview
Problem
Existing solutions for electromagnetic compatibility (EMC) and electrostatic discharge (ESD) protection between die cast housing parts of electronic control units (ECUs) are complicated and costly, and struggle to accommodate manufacturing tolerance variations.
Innovation Solution
A resilient spring-clip joining element with pairs of jaws that self-position and engage housing parts, increasing gripping force to secure them together, thereby providing EMC/ESD protection while allowing for variations in gap sizes between parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complicated EMC/ESD protection solutions such as gaskets with embedded metal elements and screw fasteners are used, then electromagnetic compatibility and electrostatic discharge protection are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (EMC protection, ESD protection, mechanical joining, and gap compensation) into a single spring-clip joining element. The resilient engagement elements simultaneously provide electrical contact for EMC/ESD protection and mechanical securing of housing parts, eliminating the need for separate gaskets and fasteners.
Solution Approach 2:
The joining element serves multiple purposes: it provides mechanical fastening through resilient engagement, maintains electrical continuity for EMC protection, offers ESD mitigation through conductive pathways, and compensates for manufacturing gaps through its spring mechanism. This multi-functional design replaces several specialized components with one universal element.
2Reliability
If gaskets with embedded metal elements and screw fasteners are used, then electromagnetic compatibility and electrostatic discharge protection are improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions (EMC protection, ESD protection, mechanical joining, and gap compensation) into a single spring-clip joining element. The resilient engagement elements simultaneously provide electrical contact for EMC/ESD protection and mechanical securing of housing parts, eliminating the need for separate gaskets and fasteners.
Solution Approach 2:
The spring-clip joining element appears to be a cost-effective alternative to expensive gaskets with embedded metal elements. By using a simpler resilient mechanism with integrated conductive features, the solution reduces material costs while maintaining protective functions.
3Stability of the object's composition
If rigid joining methods are used, then structural stability is improved, but adaptability to manufacturing tolerance variations deteriorates
Solution Approach 1:
The patent employs resilient engagement elements that can dynamically adjust to varying gap sizes between housing parts. The spring mechanism allows the joining element to flex and adapt to manufacturing tolerances while maintaining secure engagement and electrical contact, unlike rigid fasteners that require precise alignment.
Solution Approach 2:
The resilient nature of the engagement elements allows the joining system to change its physical parameters (engagement force, position) in response to varying gap conditions. This enables the same joining element to effectively accommodate different manufacturing tolerances without compromising structural stability.
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 simplifies the assembly process, reduces material costs, and ensures effective EMC/ESD protection by aligning and securing housing parts with a self-adapting M-shaped configuration that maintains closure and resistance to environmental factors.
Implementation Method 1
a resiliently biased joining element, or spring-clip... the first pair of engagement elements receives and engages with the first part of the housing by a first engagement force, and the second pair of engagement elements receives and engages with the second part of the housing by a second engagement force
Data Source
Figure 1~2
Figure 3~4
AI summary
A joining element (21), such as to provide electromagnetic shielding of assembled halves (11, 12) of an electronic control unit (10). The element (21), e.g. formed as one elongate and continuous piece from spring steel, comprises a first pair of resilient elements (22) for receiving a first half (12) of the housing, and a second pair of resilient elements (24) for receiving a second half of the housing. The elements act as jaws to position and secure the parts in aligned configuration and bridge any gap/variations in the respective adjoining edges.