On-Vehicle Electronic Module Integrating Resin Case and Connector
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Solution Overview
Problem
Conventional electronic modules with male connector housings are bulky, costly, and require extensive assembly, making it difficult to achieve downsizing and cost reduction while maintaining environmental resistance and connectivity.
Innovation Solution
An on-vehicle electronic module design that integrates a circuit board with an insulating resin member between the terminal and mounting regions, eliminating the need for a male connector housing by using a resin case with integral connector structures and adhesive bonding, allowing for external connection without additional components or solder joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a male connector housing is mounted on the circuit board to enable detachable external connection, then external connectivity is achieved, but the module size increases and manufacturing cost rises
Solution Approach 1:
The connector housing is integrated into the case as a unified structure, eliminating the need for separate connector components. The case simultaneously serves as both protective housing and connector mounting structure, reducing overall module volume while maintaining external connectivity functionality
Solution Approach 2:
The case is designed to perform multiple functions: protecting the circuit board, providing structural support, and serving as the connector housing for external connections. This multi-functional design eliminates dedicated connector components and reduces module size
2Adaptability or versatility
If a male connector housing with additional components is used for external connection, then detachable connectivity is enabled, but manufacturing cost increases due to additional components and assembly steps
Solution Approach 1:
The connector housing is merged with the case structure, eliminating the need for separate connector components and their associated assembly steps. This integration reduces both component count and assembly complexity, directly lowering manufacturing costs
Solution Approach 2:
The traditional separate connector housing component is extracted from the design and its functionality is integrated directly into the case structure, eliminating the need for additional components and reducing assembly complexity
3Strength
If the circuit board is coupled to the case using conventional methods, then structural support is achieved, but the design complexity and assembly steps increase
Solution Approach 1:
The circuit board mounting structure is integrated with the case as a unified design, eliminating separate mounting brackets or fastening mechanisms. This integration simplifies both the design and assembly processes while maintaining structural support strength
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
This design reduces module size and weight, lowers manufacturing costs, and enhances reliability and environmental sealing, while maintaining connectivity and heat dissipation capabilities.
Implementation Method 1
an insulating resin member that fixes the circuit board to a case and the circuit board are integrally formed by molding or joining and bonding
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
There is provided an on-vehicle electronic module that includes an external connecting function and environment resistant reliability similar to a previous on-vehicle electronic module and that simultaneously achieves downsizing without a male connector housing component and cost reduction due to reduction of the number of components and assembly man-hours. There are included a circuit board 1 including a mounting region 2 and a terminal forming region 3, and a case housing the mounting region 2 of the circuit board 1. Electronic components 9 and 10 are mounted on the mounting region 2. A board terminal is formed in the terminal forming region 3. The case includes a case member 13 integrally formed with a wall surface and a male connector housing 13a. The wall surface forms a case internal space 21 that houses the mounting region 2. A female connector is mounted to the male connector housing 13a. The circuit board 1 penetrates the case member 13 such that the terminal forming region 3 is exposed to a housing space 22 side of the male connector housing 13a.