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FORM 2
THE PATENTS ACT 1970
39 OF 1970
&
THE PATENT RULES 2003
COMPLETE SPECIFICATION
(SEE SECTIONS 10 & RULE 13)
1. TITLE OF THE INVENTION
“AN ELECTRONIC CONTROL UNIT”
2. APPLICANTS (S)
(a) Name: Varroc Engineering Limited
(b) Nationality: Indian
(c) Address: L-4, Industrial Area,
Waluj MIDC, Aurangabad-431136,
Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in
which it is to be performed.
2
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from the Indian provisional patent application, having
application number 202321064874, filed on 27th September 2023, incorporated herein by a
5 reference.
TECHNICAL FIELD OF THE INVENTION
The technical field of the invention relates to electronic control units (ECUs) for vehicles, more
10 specifically designing an ECU for efficiently pouring the molten potting material inside the
ECU housing.
BACKGROUND OF THE INVENTION
15 The statements in this section merely provide background information related to the present
disclosure and may not constitute prior art.
The vehicle may include a plurality of electronic control units (ECUs) associated with various
functionalities of the vehicle. Typically, the ECU includes a printed circuit board (PCB) on
20 which multiple electronic components are mounted. These components are responsible for
processing and executing various control functions within the vehicle's systems.
The housing of the ECU encompasses the PCB, providing physical protection and
environmental sealing to safeguard the sensitive electronics from external factors such as
25 moisture, dust, and vibrations. Additionally, the housing ensures proper alignment and stability
of the PCB within the ECU assembly.
A connector is also an integral part of the ECU design, facilitating communication between the
ECU and other vehicle systems or sensors. This connector ensures reliable electrical connections
30 for signal transmission and power supply to and from the ECU.
3
One specific application of an ECU is to precisely control critical engine parameters such as airfuel ratio and ignition timing in an internal combustion engine. By accurately managing these
parameters, the ECU helps optimize engine performance, improve fuel efficiency, reduce
emissions, and enhance overall drivability. The precise control provided by the ECU is essential
5 for meeting stringent emission standards and ensuring smooth operation under various driving
conditions.
The challenge in existing ECU designs is to provide an enclosure that ensures protection of
electronic components against environmental conditions such as humidity, dust, and water while
10 also ensuring proper mating with a connector. Another challenge is the filing of potting material,
which often results in droplets being deposited on the connector terminal.
Therefore, there is a need in the art for an improved ECU design that provides efficient filing of
potting materials without compromising the integrity and functionality of the connector
15 terminals or other electronic components.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts in a simplified format, that are
20 further described in the detailed description of disclosure. This summary is neither intended to
identify key or essential inventive concepts of the disclosure nor is it intended for determining
the scope of the disclosure. In an embodiment of the present disclosure, a gear actuation
mechanism in electric vehicles is disclosed.
25 The embodiments presented herein propose an electronic control unit (ECU) assembly for
vehicles in which the housing of the ECU is configured in such a way to prevent leakage of
molten potting material.
In embodiment, the ECU assembly, comprising a housing having a first end and a second end,
30 the housing being a hollow structure with an opening at each end. Further, a printed circuit board
(PCB) inserted into the housing from the second end and the PCB has various electronic
4
components mounted thereon. Furthermore, a funnel configured at one side of the housing,
having a first opening for receiving a potting material and a second opening for directing the
potting material into the housing.
5 In another embodiment, the ECU assembly has the funnel which includes an angular profile at
an end of a first inner wall directed towards the second opening in which angle of the angular
profile is 130 degrees.
In another embodiment, the ECU assembly has the funnel that includes “L” shape profile at an
10 end of a second inner wall directed towards the second opening.
In another embodiment, the ECU assembly has the second opening of the funnel which is wider
than the first opening to facilitate increased flow rate of the potting material into the housing.
15 In another embodiment, the ECU assembly has a funnel which is designed to allow an air to
escape from the first end of the housing during filling of the potting material, thereby preventing
air entrapment.
In another embodiment, the ECU assembly has the PCB which includes steps on both sides
20 adjacent to a card edge to restrict movement of the PCB towards the first end of the housing.
In another embodiment, the ECU assembly has a guide rail which is formed on the inner sides
of the housing adjacent to both the first end and the second end to facilitate insertion of the PCB
into the housing.
25
In another embodiment, the ECU assembly further comprising a groove (221) provided around
the circumference of the second end (201b) of the housing (201), wherein a sealing means (209)
is provided around the groove (221) and a plastic cap (211) is secured to the circumference of
the second end (201b) of the housing (201) by the sealing means (209).
30
In another embodiment, the sealing means (209) is a glue or a gasket.
5
In another embodiment, the ECU assembly has at least one rib which protrudes from the inner
inside of the plastic cap and configured to adhere the PCB at the second end of the housing.
5 To further clarify advantages and features of the present disclosure, a more elaborated
description of the disclosure will be rendered by reference to specific embodiments thereof,
which is illustrated in the appended drawings. It is appreciated that these drawings depict only
typical embodiments of the disclosure and are therefore not to be considered limiting of its scope.
The disclosure will be described and explained with additional specificity and detail with the
10 accompanying drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The features, nature, and advantages of the present disclosure will become more apparent from
15 the detailed description set forth below when taken in conjunction with the drawings in which
reference characters identify correspondingly throughout. Some embodiments of system and/or
methods in accordance with embodiments of the present subject matter are now described, by
way of example only, and with reference to the accompanying figures, in which:
20 Fig. 1(a) illustrates an exploded view of an electronic control unit in accordance with an
embodiment of the present disclosure;
Fig. 1(b) illustrates a cross-sectional view of the electronic control unit illustrating potting
mechanism in accordance with an embodiment of the present invention;
25
Fig. 1(c) illustrates another cross-sectional view of the electronic control unit illustrating sealing
mechanism in accordance with an embodiment of the present invention;
Fig. 1(d) illustrates a printed circuit board placement inside a housing of the electronic control
30 unit in accordance with an embodiment of the present invention;
6
Fig. 2(a) illustrates a cross-sectional view of the electronic control unit illustrating yet another
potting mechanism in accordance with an embodiment of the present invention;
Fig. 2(b) illustrates a cross-sectional view of the electronic control unit illustrating potting
5 mechanism in accordance with an embodiment of the present invention; and
Fig. 2(c) illustrates another cross-sectional view of the electronic control unit illustrating sealing
mechanism in accordance with an embodiment of the present invention.
10 It should be appreciated by those skilled in the art that any block diagram herein represents
conceptual views of illustrative systems embodying the principles of the present subject matter.
Similarly, it will be appreciated that any flow charts, flow diagrams and the like represent
various processes which may be substantially represented in computer readable medium and
executed by a computer or processor, whether such computer or processor is explicitly shown.
15
DETAILED DESCRIPTION OF THE INVENTION
The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended
to cover a non-exclusive inclusion, such that a setup, system, or method that comprises a list of
20 components or steps does not include only those components or steps but may include other
components or steps not expressly listed or inherent to such setup or system or method. In other
words, one or more elements in a system or apparatus proceeded by “comprises… a” does not,
without more constraints, preclude the existence of other elements or additional elements in the
system or apparatus.
25
In the following detailed description of the embodiments of the disclosure, reference is made to
the accompanying drawings that form a part hereof, and in which are shown by way of
illustration specific embodiments in which the disclosure may be practiced. These embodiments
are described in sufficient detail to enable those skilled in the art to practice the disclosure, and
30 it is to be understood that other embodiments may be utilized and that changes may be made
7
without departing from the scope of the present disclosure. The following description is,
therefore, not to be taken in a limiting sense.
Fig. 1(a) illustrates an exploded view of an electronic control unit in accordance with an
5 embodiment of the present disclosure. The electronic control unit (ECU) comprises a housing
(101) having a first end (101(a)) and a second end (101(b)), a printed circuit board (PCB) (103)
in which various electronics components are mounted. The housing (101) is provided with a
protruding profile (102) at one side of the second end (101(b)) of the housing (101), to
accommodate the component mounted on the PCB (103). The housing (101) is a hollow
10 structure having an opening at the first end (101(a)) and at the second end (102(b)). The housing
(101) may be made transparent or semi-transparent or non-transparent or alike.
The PCB (103) is configured to be inserted through the second end (101(b)) of the housing (101)
along the direction of the arrow shown by reference numeral (105). The PCB (103) includes a
15 card edge (103(a)) at its one end. The housing (101) includes a guide rail (104(a), 104(b)) on
both sides adjacent to the first end (101(a)) and a second end (101(b)) to facilitate the PCB (103)
to be inserted into the housing (101). The PCB (103) has steps (115(a), 115(b)) on its both sides
adjacent to the card edge (103(a)). The housing (101) in its inside having steps on its both sides
adjacent to the first end (101(a)) that matches with the steps (115(a), 115(b)) of the PCB (103)
20 to restrict the movement of the PCB (103) towards first end (101(a)) of the housing (101). The
width of the PCB (103) at one end is less (may be referred as smaller width) than width at
another end (may be referred as larger width). The housing (101) may be made such that it may
easily accommodate the PCB (103) with steps at inner side of the housing (101). The second
end (101 (b)) of the housing (101) is provided with a groove around its circumference. A sealing
25 means (109) is configured to be placed at the second end (101(b)) of the housing (101) such that
the sealing means (109) substantially matches with the grooves of the second end (101(b)) of
the housing (101). The plastic cap (111) is snap fitted/press fitted to the second end (101(b)) of
the housing (101) such that the sealing means (109) is adequately fits against the circumference
of the second end (101(b)) of the housing (101) thereby maintaining the sealing. The purpose of
30 the sealing means (109) is to maintain proper sealing between the second end (101(b)) of the
housing (101) and the plastic cap (111). The molten potting material (107) is poured from the
8
first end (101(a)) of the housing (101) with required quantity and up to a height such that it does
not damage the edge of the PCB (103). Further, A plurality of guides (106(a)) protruding from
the outer surface of the housing (101) adjacent to a first end (101(a)) of the housing (101). At
least a one stopper (106(b)) is provided between the plurality of guides (106(a)).
5
Fig. 1(b) illustrates a cross-sectional view of the electronic control unit illustrating a potting
mechanism in accordance with an embodiment of the present invention. The PCB (103) inserted
through the guide rails (104(a), 104(b)) formed at inner side of the housing (101). The potting
material (107) is poured through the first end (101(a)) of the housing (101) through a channel
10 (113). The potting material (107) travels through the channel (113) in such a way that the potting
material (107) is directly poured to the bottom of the housing (101) and gradually fills up the
housing (101) till it reaches to the required height below the connecting terminals of a card edge
(103(a)), covering an inside space of the housing (101) up to a certain height and thereby the
potting material (107) is cured. The potting material (107) may be resin & hardner, and the ratio
15 may be 100:25. The potting material (107) is poured only up to a certain height such that a
portion of the PCB (103) is visible. The portion of the PCB (103) which is visible may be a card
edge (103(a)) connector which will fit to a connector.
In another embodiment of the present invention, the potting material (107) may be poured
20 through the first end (101(a)) of the housing (101) through another channel (113(a)) opposite to
the channel (113). The portion of the PCB (103) which is visible may be the card edge (103(a))
connector which will fit to a connector.
Fig. 1(c) illustrates another cross-sectional view of the electronic control unit illustrating sealing
25 mechanism in accordance with an embodiment of the present invention. The sealing means
(109) is secured to the second end (101(b)) of the housing (101) so as to avoid leakage of the
potting material (107). The sealing means (109) may be a glue which may be solid or liquid. In
an alternate embodiment of the present invention sealing means (109) may be any elastic or
non-elastic material known in the art or gasket or rubber or thin cotton rope or thin piece of cloth
30 or alike. The purpose of the sealing means (109) is to maintain proper sealing between the
second end (101(b)) of the housing (101) and the plastic cap (111).
9
Fig. 1(d) illustrates a printed circuit board placement inside a housing of the electronic control
unit in accordance with an embodiment of the present invention. The housing (101) includes a
guide rail (104(a), 104(b)) which facilitates sliding the PCB (103) inside the housing (101) till
5 the resting point and at the end triangle shape projection (not shown in Fig. 1(d)) given to selflock the PCB (103) in the required location.
Fig. 2(a) illustrates a cross-sectional view of the electronic control unit illustrating yet another
potting mechanism in accordance with an embodiment of the present invention and Fig. 2(b)
10 illustrates a cross-sectional view of the electronic control unit illustrating potting mechanism in
accordance with an embodiment of the present invention. The housing (201) is the external
casing or enclosure of the ECU, designed to protect the internal components from environmental
factors such as moisture, dust, and mechanical impacts. The housing (201) has two ends, a first
end (201(a)) is likely the top part of the housing (201) & a second end (201(b)) is the bottom or
15 rear part of the housing (201) through which the printed circuit board (PCB) (203) is inserted.
The PCB (203) is the core component of the ECU, where various electronic components are
mounted. The PCB (203) performs the control and processing functions of the ECU. The PCB
(203) is inserted into the housing (201) from the second end (201(b)). The housing (201)
includes a guide rail (204(a), 204(b)) formed at inner side of the housing (201) and at both sides
20 adjacent to the first end (201(a)) and a second end (201(b)) to facilitate the PCB (203) to be
inserted into the housing (201).
The housing (201) is a hollow structure having an opening at the first end (201(a)) and at the
second end (201(b)). The PCB (203) has steps (215(a), 215(b)) on its both sides adjacent to the
25 card edge (203(a)). The housing (201) in its inside having steps on its both sides adjacent to the
first end (201(a)) that matches with the steps (215(a), 215(b)) of the PCB (203) to restrict the
movement of the PCB (203) towards first end (201(a)) of the housing (201). The width of the
PCB (203) at one end is less (may be referred as smaller width) than width at another end (may
be referred as larger width). The housing (201) may be made such that it may easily
30 accommodate the PCB (203) with steps at inner side of the housing (201). The second end (201
(b)) of the housing (201) is provided with a groove (221) around its circumference. A sealing
10
means (209) is configured to be placed at the second end (201(b)) of the housing (201) such that
the sealing means (209) substantially matches with the grooves (221) of the second end (201(b))
of the housing (201). The plastic cap (211) is snap fitted/press fitted to the second end (201(b))
of the housing (201) such that the sealing means (209) is adequately secured against the
5 circumference of the second end (201(b)) of the housing (201) thereby maintaining the sealing.
The securing of the sealing means (209) depends upon selection of the sealing means (209). The
purpose of the sealing means (209) is to maintain proper sealing between the second end
(201(b)) of the housing (201) and the plastic cap (211). When a glue is used as sealing means
(209), which spread against the circumference of the second end (201(b)) of the housing (201),
10 then cured between the plastic cap (211) and the second end (201(b)) of the housing (201)
thereby maintaining the sealing. When an elastic material such as a rubber is used as sealing
means (209) and when the plastic cap (211) is snap fitted/press fitted to the second end (201(b))
of the housing (201) such that the rubber is adequately compressed against the circumference of
the second end (201(b)) of the housing (201) thereby maintaining the sealing. The molten
15 potting material (205) is poured from the funnel (207) of the housing (201) with required
quantity and up to a height such that it does not damage the edge of the PCB (203). Further, A
plurality of guides (not shown in Fig. 2(a), however same can be referred from the Fig. 1(a))
protruding from the outer surface of the housing (201) adjacent to a first end (201(a)) of the
housing (201). At least one stopper (not shown in Fig. 2(a), however same can be referred from
20 the Fig. 1(a)) is provided between the plurality of guides.
After the PCB is inserted into the housing (201), a sealing process is required to ensure that the
housing (201) is properly sealed and protected. A sealing means (209) (as shown in Fig. 2(c))
is applied in a groove (221) located on the bottom side of the housing (201). The groove (221)
25 is provided around the circumference of the second end (201(b)) of the housing (201). This
groove (221) is strategically placed to bond the housing (201) and a plastic cap (211), ensuring
a secure and tight seal. The plastic cap (211) is then pushed into the second end (201(b)) of the
housing (201). The plastic cap (211) helps to close the housing (201) and fits the sealing means
(209), thereby creating a proper seal. This arrangement ensures prohibiting leakage of molten
30 potting material (205) between the housing (201) and the plastic cap (211). The potting material
(205) is used to encapsulate the PCB (203) and other internal components within the housing
11
(201). The potting material (205) provides protection against vibration, moisture, and other
environmental factors, enhancing the durability and reliability of the ECU.
A funnel (207) is configured at the one side of the housing (201). The funnel (207) having a first
5 opening (207 (a)) through which the potting material (205) is poured and the funnel (207) having
a second opening (207(b)) through which the potting material (205) enters into the housing (201).
The second opening (207(b)) has substantially more width or more diameter or alike than the
first opening (207(a)).
10 The funnel (207) is designed in such a way that the potting material (205) will be poured through
the first opening (207(a)) of the funnel (207) and it will travel at a certain angle till bottom of
the funnel (207) and through the second opening (207(b)) of the funnel (207) to enter into the
housing (201). Further the potting material (205) entering the second opening (207(b)) of the
funnel (207) is divided by the PCB (203) which divides the flow of the potting material (205)
15 to its both sides.
The potting material (205) travels inside the space of the housing (201) up to a certain height
such that some portion of the PCB (203) is visible. The portion of the PCB (203) which is visible
may be a card edge (203(a)) connector which will fit to a connector.
20
The potting material (205) has a high viscosity and due to its low flow rate, the required time
for filling the potting material (205) has an impact on rate of production. Considering this and
to increase the flow rate and reduce filling time, the second opening (207(b)) of the funnel (207)
is being configured to an angle of about 130 degrees.
25
The funnel (207) includes a first inner wall (217(a)) and a second inner wall (219(a)), wherein
the first inner wall (217(a)) and the second inner wall (219(a)) originates from the first opening
(207 (a)) of the funnel (207) and terminates to the second opening (207(b)) of the funnel (207).
30 The first inner wall (217(a)) of the funnel (207) has an angular profile (217(b)) at its end which
is towards the second opening (207(b)) of the funnel (207). In one preferred embodiment, the
12
angle of the angular profile (217(b)) is about 130 degrees. However, the angular profile may
have any other angle close to 130 degrees.
The second inner wall (219(a)) of the funnel (207) has a substantially a “L” shape profile 219
5 (b) which is towards the second opening (207(b)) of the funnel (207).
According to an embodiment, when the molten potting material (205) poured through the funnel
(207), the air flows out from the first end (201(a)) of the housing (201) and the issue of air
entrapment is avoided.
10
In an embodiment, the potting material (205) is poured through the side funnel (207) of the
housing (201). The potting material (205) travels from first portion (207a) of the funnel towards
second portion (207b). At the second portion (207(b)) of the funnel (207) the PCB (203) makes
partition at an exit portion of the funnel (207). As the second portion (207b) of the funnel (207)
15 is wider than first portion (207a) which facilitates increased travel velocity/flow rate of the
potting material (205) towards the bottom side of the housing (201), which reduces filling time
and avoids the blockage issue at an entrance of the funnel (207). Therefore, the present invention
gives advantages of increased production rate and reduces cost of operation.
20 Fig. 2(c) illustrates another cross-sectional view of the electronic control unit illustrating sealing
mechanism in accordance with an embodiment of the present invention. A sealing means (209)
is applied to the second end (201(b)) of the housing (201) to avoid leakage of the potting material
(205). The purpose of the sealing means (209) is to maintain proper sealing between the second
end (201(b)) of the housing (201) and a plastic cap (211). When the plastic cap (211) snap
25 fitted/press fitted with second end (201(b)) of the housing (201) the sealing means (209) gets
adequately secured against the circumference of the second end (201(b)) of the housing (201)
thereby maintaining the sealing. The sealing means matches the grooves (221) of the second
end (201(b)) of the housing (201) and makes proper sealing between second end (201 (b)) and
the plastic cap (211).
30
13
In an embodiment of the present invention at least one rib (211(a)) protruding from inside of the
plastic cap (211). The rib (211(a)) configured to adhere the PCB (203) from the second end
(201(b)) of the housing (201). The advantages of the present ECU design are that it provides
ease of filling potting material and provides an easy path of air to exit the housing cavity during
5 filling of potting material to avoid air entrapment. Also, the blocking issue of the funnel is
avoided.
The illustrated steps are set out to explain the exemplary embodiments shown, and it should be
anticipated that ongoing technological development will change the manner in which particular
10 functions are performed. These examples are presented herein for purposes of illustration, and
not limitation. Further, the boundaries of the functional building blocks have been arbitrarily
defined herein for the convenience of the description. Alternative boundaries can be defined so
long as the specified functions and relationships thereof are appropriately performed.
Alternatives (including equivalents, extensions, variations, deviations, etc., of those described
15 herein) will be apparent to persons skilled in the relevant art (s) based on the teachings contained
herein. Such alternatives fall within the scope and spirit of the disclosed embodiments.
List of Reference Numbers:
101 Housing
20 101(a) First end of housing
101(b) Second end of housing
102 Protruding profile
103 Printed circuit board
103(a) Card edge
25 104(a), 104(b) Guide rails
105 Arrow
106(a) Guides
106(b) Stopper
107 Potting material
30 109 Sealing means
111 Plastic cap
14
113 Channel
113(a) Another channel
115 (a) Steps of the printed circuit board at one side
115 (b) Steps of printed circuit board at another side
5 201 Housing
201(a) First end of housing
201(b) Second end of housing
203 Printed circuit board (PCB)
203(a) Card edge
10 204(a), 204(b) Guide rails
205 Potting material
207 Funnel
207(a) First opening of the funnel
207(b) Second opening of the funnel
15 209 Sealing means
211 Plastic cap
211 (a) Rib
215 (a) Steps of the printed circuit board at one side
215 (b) Steps of printed circuit board at another side
20 217 (a) First inner wall
217 (b) Angular profile
219 (a) Second inner wall
219 (b) “L” shape profile
221 Groove
25
30
15
We Claim:
1. An electronic control unit (ECU) assembly, comprising:
a housing (201) having a first end (201a) and a second end (201b), the housing
5 (201) being a hollow structure with an opening at each end;
a printed circuit board (PCB) (203) inserted into the housing (201) from the
second end (201b), wherein the PCB (203) has various electronic components mounted
thereon; and
a funnel (207) configured at one side of the housing (201), having a first opening
10 (207a) for receiving a potting material (205) and a second opening (207b) for directing the
potting material (205) into the housing (201).
2. The ECU assembly as claimed in claim 1, wherein the funnel (207) includes an angular
profile (217b) at an end of a first inner wall (217a) directed towards the second opening
15 (207b), wherein angle of the angular profile (217b) is 130 degrees.
3. The ECU assembly as claimed in claim 1, wherein the funnel (207) includes “L” shape
profile (219b) at an end of a second inner wall (219a) directed towards the second
opening (207b).
20
4. The ECU assembly as claimed in claim 1, wherein the second opening (207b) of the
funnel (207) is wider than the first opening (207a) to facilitate increased flow rate of the
potting material (205) into the housing (201).
25 5. The ECU assembly as claimed in claim 1, wherein the funnel (207) is designed to allow
an air to escape from the first end (201a) of the housing (201) during filling of the potting
material (205), thereby preventing air entrapment.
6. The ECU assembly as claimed in claim 1, wherein the PCB (203) includes steps (115a,
30 115b) on both sides adjacent to a card edge (203a) to restrict movement of the PCB (203)
towards the first end (201a) of the housing (201).
16
7. The ECU assembly as claimed in claim 1, wherein a guide rail (204a, 204b) formed on
the inner sides of the housing (201) adjacent to both the first end (201a) and the second
end (201b) to facilitate insertion of the PCB (203) into the housing (201).
5
8. The ECU assembly as claimed in claim 1, further comprising:
a groove (221) provided around the circumference of the second end (201b) of
the housing (201), wherein a sealing means (209) is provided around the groove (221);
and
10 a plastic cap (211) is secured to the circumference of the second end (201b) of
the housing (201) by the sealing means (209).
9. The ECU assembly as claimed in claim 8, wherein the sealing means (209) is a glue or
a gasket.
15
10. The ECU assembly as claimed in claim 8, wherein at least one rib (211a) protrudes from
inner inside of the plastic cap (211), configured to adhere the PCB (203) at the second
end (201b) of the housing (201).