Bulkhead flatwire integration units

Description

TECHNICAL FIELD

The present invention generally relates to underhood electronics in a motor vehicle, and more particularly relates to integration of these electronics.

BACKGROUND INFORMATION

Underhood electronics are becoming more prevalent as more functions are contained under hood, such as an antilock braking system, engine control, transmission control, and variable valve timing, as well as numerous sensors and actuators. Currently, heavily sealed modules are installed underhood which are used to house various electronic boxes. These modules are very costly due to the high level of sealing and protection required, as well as the need for cooling of the electronics. Typically these modules include aluminum cast housings with cooling features, as well as a significant amount of bracketry to support the electronic boxes in the entire module. Further, these modules require connectors, pigtails, and wiring harnesses that are associated with each of the underhood electronic devices. Accordingly, there exists a need to provide an electronic system for the underhood devices of a motor vehicle which reduces the costs, packaging, volume and weight of the system, while increasing the serviceablilty and packaging efficiency of the system.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an electronic system for a motor vehicle having a bulkhead separating an engine compartment and a passenger compartment, the engine compartment having an electronic device for performing a vehicle function. The electronic system generally includes an electronic panel having circuitry plated on a surface thereof as well as electronic components attached thereto. The circuitry connects the electronic components for operation of the electronic device in the engine compartment. A flatwire bus electronically connects the electronic panel and the electronic device in the engine compartment for transmitting signals therebetween. The electronic panel is directly connected to the bulkhead.

The electronic panel may be mounted to either the passenger side or the engine side of the bulkhead. Preferably, the electronic panel is an enclosure having an interior and an exterior, wherein the electronic components and circuitry are formed on the interior of the electronic panel. Alternatively, the electronic components and the circuitry may be formed on the exterior of the electronic panel. The system may further include a cover connected to the bulkhead enclosing the electronic panel for environmental protection.

The bulkhead typically includes an aperture, and the electronic panel may engage the aperture for plugging the bulkhead to provide environmental protection to the passenger compartment The electronic panel can be linked to the electronic devices within the passenger compartment via the aperture. Preferably, the electronic panel is vertically mounted such that the electronic components are vertically spaced. In that way, the hotter components may be mounted on a lower half of the electronic panel, or more specifically, the holler components may be mounted vertically below the cooler components. Additional electronic panels may be employed and attached to the bulkhead, as numerous electronic devices within the engine compartment may be controlled by the integrated system.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:

FIG. 1 is an exploded front perspective view of a vehicle bulkhead and the electronic panels forming a portion of the electronic system constructed in accordance with the teachings of the present invention;

FIG. 2 is a plan view of a first electronic panel of the electronic system;

FIG. 3 is a plan view of a second electronic panel of the electronic system;

FIG. 4 is a front view showing the electronic panels attached to the bulkhead;

FIG. 5 is an exploded view, partially cut away, taker about the dashed circle 5 in FIG. 4;

FIG. 6 is an exploded view taken about the dashed circle 6 of FIG. 4; and

FIG. 7 is a perspective view of a motor vehicle having the electronic system of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the figures, FIG. 1 depicts a first electronic panel 20 and a second electronic panel 22 for attachment to a vehicle bulkhead 10. The bulkhead is typically constructed of sheet metal for providing a barrier between an engine compartment 12 (FIG. 7) and a passenger compartment 14 (FIG. 7). The invention consolidates standard underhood electronic systems into one, or as shown, two large electronic panels, where all underhood electronics are located. The electronics are then interfaced to all of the electronic devices in the engine compartment, including sensors and actuators, via flatwire busses and flatwire takeouts from the electronic panels.

Accordingly, the electronic system of the present invention reduces the volume used to package underhood electronics, as well as reduces the weight and cost by eliminating large wire harnesses, module housings, bracketry, and standard connector systems. Additionally, the use of one or two electronic panels provides easier serviceability of the electronic system. Finally, the vehicle bulkhead may include large apertures which are sized to receive the electronic panels. In this way, the analogous section of metal of the bulkhead may be replaced with the preferred plastic material of the module, which is much lighter, while still providing the necessary mechanical and environmental protection between the engine compartment and the passenger compartment.

As shown in FIGS. 2 and 3, the electronic panels each include a substrate 24, preferably constructed of a polymer or plastic. The substrate 24 may be molded and may be formed into many different shapes or configurations as shown in the figures. The substrate 24 defines an outer surface 26 which has circuitry 28 plated on that surface of the substrate 24. The circuitry 28 interconnects various electronic components 30 which are designed for operation of the electronic device in the engine compartment 12. Such electronic devices include anti-lock braking systems, engine control units, transmission control units, and valve timing, as well as numerous sensors and actuators. The electronic panels may contain all the electronics to operate electronic devices within the passenger compartment 14 as well, such as amplifiers, airbags, audio/radio, or global positioning systems and the like.

Turning back to FIG. 1, the plastic substrate 24 of the electronic panels 20, 22 can be formed into an enclosure having an interior and an exterior Accordingly, it will be recognized by those skilled in the art that the circuitry 28 end the electronic components 30 may be located on the interior of the panels 20, 22 and more specifically, the enclosure formed by the plastic substrate 24. This will provide for added environmental protection for the circuitry 28 and the electronic components 30, ensuring reliable operability. As shown in the figures, the circuitry is plated on the plastic substrate 24 and the electronic components 26 are mounted to the outer surface 26 of the panels 20, 22.

When the circuitry 28 and electronic components 30 are formed on the outer surface 26 of the electronic panels 20, 22, additional protection can be added. This protection can be a conformal coating, or it can take the form of a cover, which can be constructed of plastic, or metal or a hybrid composition including metalized films. These covers or coatings can provide additional environmental protection as well as electromagnetic interference EMI shielding.

As shown in FIG. 4, the electronic panels 20, 22 are attached directly to the vehicle bulkhead 10, and more specifically the engine side 11 of the bulkhead 10. Accordingly, the bulkhead provides structural support as well as thermal heat sinking to the circuitry 28 and electronic components 30.

The electronic panels 20, 22 also provide a secondary structural benefit. As shown in FIG. 1, the vehicle bulkhead 10 can include various apertures 16 which provide pass-through opportunities. Accordingly, the electronic panels 20, 22 preferably engage these apertures 16 and operate as bulkhead plugs or dash panel inserts to provide additional mechanical support to the sheet metal used in the bulkhead 10. As a dash panel insert, the electronics can easily interface with the cockpit system or house much of the cockpit electronics to improve design freedom in the interior passenger compartment 14.

The electronic panels, 20, 22 are designed to engage the bulkhead 10 and still provide pass-throughs as needed for the tubing or other items, i.e., for the heating and ventilation air conditioning (HVAC) system. These features are shown in the enlarged views of FIGS. 5 and 6 depicting the panels 20, 22 attached to the bulkhead while still providing pass-throughs through the bulkhead 10.

The electronic panels 20, 22 can be constructed of a metal such as cast aluminum, steel, magnesium or various alloys. These panels 20, 22 may also be constructed of a filled plastic such as acrylonitrite butadiene styrene ABS, nylon, polybutylene terephthalate (PBT) or ultem. A composite structure may also be employed such as epoxy-carbon fiber, or overmolded steel structures. The circuitry 28 can be applied to the interior or exterior of the panels 20, 22 through numerous methods such as plating, bonding, etching, or in-molding. It will also be recognized that a flat flexible circuit can also provide the necessary circuitry 28 to the panel 20, 22, which can be attached to the substrate 24 by way of mechanical connectors such as pins, clips, Velcro and the like, as well as by adhesive connection preferably utilizing a thermally conductive adhesive.

As illustrated in FIG. 7, the electronic panels 20, 22 (FIG. 4) may be electronically connected to the electronic devices within the engine compartment 12 by way of a flatwire bus system which can include flatwire takeouts. As depicted, a first flatwire bus 40 extends from the first electronic panel 20 through an aperture 16 (FIG. 1), and has numerous flatwire takeouts 41 which are connected to a device such as the injectors and ignition coils on the engine 18 in the engine compartment 12. A second flatwire bus 42 extends from the second electronic panel 22 and includes flatwire takeouts 43 connected to a lighting system 19, and more particularly to the front lights of the vehicle.

The flatwire busses and pickups can be mechanically and metallurgically connected directly to the circuitry on the electronic panels 20, 22. Alternatively, the use of flatwire connectors allows for simple servicing of each modular unit, and these connectors may also be used. The flatwire bus system 40, 42 as well as the takeouts 41, 43 may be attached directly to underhood structures where available, and alternately may be supported by a thin plastic sheet mounted to it. The sheet can be flexible or pre-formed to route the flatwire as desired. The flatwire bus can also be coated with silicone or nylon, or overmolded with a material such nylon, polystyrene, ABS-polycarbonate, to provide added protection within the engine compartment 12.

It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.