Stepped Flange Case Assembly to Eliminate Corner Gaps
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Solution Overview
Problem
Conventional electronic control device cases made of metal plates have gaps at their corners due to spring back during bending, allowing foreign matter entry and potential short-circuits, necessitating resin or cushion filling to prevent interference.
Innovation Solution
The design positions first and second flanges on different planes, forming narrow slits instead of large gaps, eliminating the need for resin filling and allowing screwless assembly with improved workability and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flanges are formed by bending metal plates considering spring back, then the flanges can be assembled without interference, but large gaps are caused at the corners allowing foreign matter entry
Solution Approach 1:
The patent positions the first flange and second flanges on different planes (first plane and second plane respectively), creating a stepped configuration. This dimensional change allows the flanges to engage the front plate edges effectively without requiring large gaps to accommodate spring back, thereby preventing foreign matter entry while maintaining ease of manufacture.
2Reliability
If resin or cushion material is used to fill gaps, then foreign matter entry is prevented, but device complexity and material costs increase
Solution Approach 1:
The patent removes the need for resin or cushion material by redesigning the flange configuration. The stepped flange structure inherently prevents gap formation at corners, eliminating the requirement for additional sealing components and reducing device complexity while maintaining reliability.
Solution Approach 2:
The flange structure itself provides the gap prevention function through its stepped configuration, eliminating the need for separate sealing materials. The first flange and second flanges work together to naturally close gaps at corners without external assistance.
3Ease of manufacture
If large gaps are provided at corners to prevent flange interference, then assembly is easier, but foreign matter can enter and cause short-circuits
Solution Approach 1:
By positioning flanges on different planes, the patent creates a stepped structure that allows easy assembly without large gaps. The dimensional separation enables the flanges to engage properly while minimizing gap size to prevent foreign matter entry, resolving the contradiction between assembly ease and protection against harmful factors.
4Strength
If screw fixation is used to secure the cover, then structural strength is improved, but assembly convenience and productivity are reduced
Solution Approach 1:
The stepped flange structure provides self-fixing capability through its geometric configuration. The first flange and second flanges naturally hold the cover in place through their positioning on different planes, eliminating the need for screws while maintaining structural strength and improving assembly productivity.
Solution Approach 2:
The patent replaces the mechanical screw fixation system with a geometric interlocking system formed by the stepped flanges. This substitution eliminates the need for fastening components and simplifies the assembly process while maintaining adequate structural strength.
Data Source
AI summary
An electronic control device case prevents a gap provided therein. The electronic control device case includes: a body case including a bottom plate and a pair of side walls bent at and extended from both ends of the bottom plate and having a front opening; and a cover including a front plate closing the front opening of the body case. The body case includes a first flange bent at a front end of the bottom plate, and second flanges bent at respective front ends of the pair of side walls. The first flange is positioned on a first plane. The second flanges are positioned on a second plane different from the first plane. The first flange pushes a back surface at a lower edge of the front plate of the cover. The second flanges push front surfaces at both side ends of the front plate of the cover. In this configuration, the edge of the front plate of the cover is sandwiched and held between the first flange and each second flange.