Vehicle Control Unit Interface Integration
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Solution Overview
Problem
Existing control units for passenger protection in vehicles are complex and costly to manufacture, with inefficient electrical connections and inadequate water resistance, particularly due to horizontal plug connections that complicate assembly and increase the risk of water ingress.
Innovation Solution
A control unit design featuring a plastic base and cover with an integrated pin strip interface, allowing for vertical electrical connections and improved water resistance through a flush finish and IP52-rated sealing, eliminating the need for a separate plastic body for the interface and enhancing assembly simplicity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate plastic body for the interface is used, then the electrical connection structure is more robust, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the interface directly into the plastic cover of the housing, eliminating the need for a separate plastic body for the interface. The interface consists of contact pins that are directly molded into or mounted on the plastic cover, which already serves as the housing structure. This merging of functions reduces part count, simplifies assembly, and lowers manufacturing cost while maintaining reliable electrical connections.
2Ease of operation
If horizontal plug connections are used, then the connector can be easily attached, but water resistance is compromised and assembly becomes more complex
Solution Approach 1:
Instead of using the conventional horizontal plug connection, the patent inverts the connection orientation to vertical. The mating connector is inserted vertically into the housing through the plastic cover, with the connection axis perpendicular to the circuit board. This vertical orientation allows the plastic cover to effectively seal around the connector, preventing water ingress while maintaining ease of attachment through the opening in the cover.
3Adaptability or versatility
If multiple separate components are used for the housing and interface, then each component can be optimized independently, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent combines the housing and interface into a single integrated plastic cover component. The plastic cover serves dual functions as both the protective housing and the interface carrier. The contact pins of the interface are either directly molded into the plastic cover or mounted on it, eliminating the need for separate housing and interface components. This integration simplifies the manufacturing process, reduces assembly steps, and lowers overall production cost.
Data Source
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AI summary
The invention relates to a control unit and a method for assembling such a control unit for personal protection means for a vehicle. A circuit board is installed between a plastic cover and a plastic floor. An interface for an electrical connection with at least one additional vehicle component is arranged on the circuit board. At least one opening is provided in the plastic cover for the electrical connection.