Method and structure for limiting cover deflection in an ECU when exposed to high altitude environments

1. An engine control unit (ECU) comprising:

a housing,

a cover sealingly engaged with the housing,

a circuit board disposed in the housing,

support structure disposed in the housing between the cover and the circuit board so as to be adjacent to an inner surface of the cover,

at least one fastener coupling both the support structure and the circuit board to the housing, and

an adhesive bonding at least one portion of the support structure to at least one portion of the inner surface of the cover, the adhesive contacting and disposed between the at least one portion of the support structure and the inner surface of the cover,

wherein the support structure is constructed and arranged to limit deflection of the cover when internal pressure increases in the ECU,

wherein the circuit board includes a mounting bore there-through, and the support structure includes a mounting portion having a bore there-through, the at least one fastener extending through the bore of the support structure and through the mounting bore of the circuit board in threaded engagement with the housing, the mounting bore of the circuit board, the bore of the mounting portion of the support structure and the at least one fastener are disposed in a longitudinally and laterally central portion of the housing, and

wherein the at least one fastener comprises a single fastener.

2. The ECU of claim 1 , wherein the cover is composed of stamped metal and the support structure is a metal support structure.

3. The ECU of claim 1 , wherein the support structure is an elongated, rigid plate.

4. The ECU of claim 1 , wherein the at least one portion of the support structure is located generally centrally of the cover.

5. The ECU of claim 4 , wherein the cover is generally rectangular and the support structure extends substantially between opposing sides of the cover.

6. The ECU of claim 4 , wherein the cover is generally rectangular and the support structure extends substantially diagonally between opposing corners of the cover.

7. The ECU of claim 1 , wherein the at least one portion of the support structure comprises at least one generally planar surface, the adhesive is disposed between the inner surface of the cover and the at least one generally planar surface, and the at least one generally planar surface of the support structure is in spaced relation with the mounting portion so that the at least one fastener is in a plane different from a plane of the at least one generally planar surface.

8. The ECU of claim 1 , wherein the at least one portion of the support structure comprises a first generally planar portion and a second generally planar portion, the first and second generally planar portions being disposed adjacent the cover, the mounting portion having a first end extending from the first generally planar portion and a second end extending from the second generally planar portion, the bore of the mounting portion is disposed at a longitudinally central portion of the mounting portion, and an area of the mounting portion surrounding the through-bore is at a different elevation within the housing relative to an elevation of the first and second generally planar portions.

9. The ECU of claim 1 , wherein the at least one fastener is spaced apart from and does not contact the cover, and the adhesive is spaced apart from and does not contact the housing.

10. An engine control unit (ECU) comprising:

a housing,

a cover sealingly engaged with the housing,

a circuit board disposed in the housing,

a support structure disposed in the housing between the cover and the circuit board so as to be generally adjacent to an inner surface of the cover,

at least one fastener coupling both the support structure and the circuit board to the housing, and

an adhesive bonding at least one portion of the support structure to the inner surface of the cover, the adhesive being spaced from and not contacting the housing,

wherein the support structure is constructed and arranged to limit outward deflection of the cover when internal pressure increases in the ECU, and

wherein the at least one fastener comprises a single fastener.

11. The ECU of claim 10 , wherein the circuit board includes at least one mounting bore there-through, and the support structure includes at least one mounting portion having a bore there-through, the at least one fastener extending through the bore of the support structure and through the mounting bore of the circuit board in threaded engagement with the housing, the mounting bore of the circuit board, the bore of the mounting portion of the support structure and the at least one fastener are disposed in a generally central portion of the housing and in a longitudinally central portion of the support structure.

12. The ECU of claim 11 , wherein the support structure comprises a first planar portion and a second planar portion, the first and second planar portions being disposed adjacent the cover, the mounting portion is disposed between the first planar portion and the second planar portion, and an area of the mounting portion surrounding the through-bore is at a different elevation within the housing relative to an elevation of the first and second planar portions.

13. The ECU of claim 10 , wherein the at least one fastener is spaced from and does not contact the cover.

14. The ECU of claim 10 , wherein the support structure is metal.

15. The ECU of claim 11 , wherein the at least one fastener comprises only one fastener.

16. The ECU of claim 10 , wherein the at least one portion of the support structure comprises at least one planar surface, the support structure includes a mounting portion having a bore therethrough, the adhesive is disposed between the inner surface of the cover and the at least one planar surface, and the at least one planar surface of the support structure is in spaced relation with the mounting portion so that the at least one fastener is in a plane different from a plane of the at least one planar surface.

17. The ECU of claim 10 , wherein the housing includes a portion that is along a side of the ECU that is opposite a side of the ECU at which the cover is located such that the at least one fastener, the support structure and the adhesive limit the cover from deflecting toward and away from the portion of the housing.

18. The ECU of claim 1 , wherein the housing includes a portion that is along a side of the ECU that is opposite a side of the ECU at which the cover is located such that the at least one fastener, the support structure and the adhesive limit the cover from deflecting toward and away from the portion of the housing.

19. An engine control unit (ECU) comprising:

a housing,

a cover sealingly engaged with the housing,

a circuit board disposed in the housing,

a support structure disposed in the housing between the cover and the circuit board so as to be generally adjacent to an inner surface of the cover,

at least one fastener coupling both the support structure and the circuit board to the housing, and

an adhesive bonding at least one portion of the support structure to the inner surface of the cover, the adhesive being spaced from and not contacting the housing,

wherein the support structure is constructed and arranged to limit outward deflection of the cover when internal pressure increases in the ECU,

wherein the circuit board includes at least one mounting bore there-through, and the support structure includes at least one mounting portion having a bore there-through, the at least one fastener extending through the bore of the support structure and through the mounting bore of the circuit board in threaded engagement with the housing, the mounting bore of the circuit board, the bore of the mounting portion of the support structure and the at least one fastener are disposed in a generally central portion of the housing and in a longitudinally central portion of the support structure, and

wherein the at least one fastener comprises only one fastener.