Patent Grant
7331801
Printed circuit boards (PCBs) are used in a wide variety of electronic devices including household appliances, motor vehicles, computers, and even children's toys. The PCBs are generally mounted within a housing that protects the PCB and facilitates installation into a particular application. In most cases, the PCB is connected to the electronic devices through a plug-in and mating connector combination that attaches to the PCB through an opening in the housing. The plug-in connector includes a plurality of wires or “pins” that extend between the mating connector and the PCB. The PCB may thus be integrated into the electrical device as a modular component and easily installed or removed for service or replacement by connecting or disconnecting the plug-in connector. In one example, an electrical system for a motor vehicle employs a PCB housed within an aluminum casting and mounted on an interior surface of the vehicle. A plug-in connection header is assembled as part of the housing to allow the mating connector to interface with the PCB. The housing thus generally protects the PCB from contaminants and damage, while the connection header provides a reliable electrical connection between the electrical system and the PCB.
In known configurations, connection headers may employ a connector shroud that retains pins for contact with the PCB, and receives a mating connector for coupling with the pins. The connector shroud extends beyond a bend point of the pins to attach to the PCB housing. The connector shroud, therefore, must have a tall profile to allow pin bending tools to access the pins that are inserted into the connection header during assembly. Taller header profiles generally increase the overall size of the device and may require complex part assemblies that are expensive to produce in mass manufacturing environments. Further, connector pins are generally thin wires that are delicate and susceptible to bending or misalignment, as may occur during shipment or installation. Known connection headers therefore typically include an alignment feature, which aligns the pins for contact with the PCB. However, known alignment features generally do not withstand vibration and shock, and may allow pins to become misaligned or dislodged from the PCB during assembly and use.
Accordingly, there is a need in the art for a connection header, which provides a low profile to minimize space in the housing, allows for efficient assembly, and protects connector pins from misalignment during assembly and operation.
Various embodiments directed to an electrical connection header for an electrical device and a method for assembling an electrical connection header for an electrical device are disclosed herein. An illustrative embodiment of an electrical connection header includes a plurality of electrical pins, each of which has a first portion and a second portion oriented generally orthogonal to each other. The pins may be inserted to a connector shroud, which defines a plurality of apertures for receiving the first portions of the pins. A hood may be secured to the connector shroud such that the hood extends beyond a bend point of at least one of the pins.
An illustrative embodiment of a method for assembling a connection header may include inserting a first portion of a plurality of pins into a plurality of apertures defined by a connector shroud. The method may further include bending the pins to form a second portion of each pin that is oriented generally orthogonal to the first portion of the pins, and securing a hood to the shroud such that the hood extends beyond a bend point of at least one of the pins.
A plug-in connector for an electrical device is provided. The plug-in connector generally includes a plurality of pins that are inserted into a connector shroud and a hood, which attaches to the connector shroud and extends beyond a bend point of the pins. The configuration of the hood allows for bending tools to freely access the pins during assembly. The plug-in connector may also include a pin alignment guide to engage the pins and align them with a printed circuit board (PCB). The pin alignment guide may include at least one feature for abutting a top surface of a PCB housing to prevent the pin alignment guide from being displaced, and especially from contacting the PCB.
Pin block 114 may be integrally formed within connector shroud 106, such as by a molding process. Other known configurations for pin block 114 may be employed. Pin block 114 defines a plurality of apertures 116a,b,c,d, which may be arranged in four spaced rows for receiving four corresponding rows of pins 110a,b,c,d. Pins apertures 116 may be arranged in a greater or lesser number of rows, or other known configurations, according to a desired arrangement of pins 110. A first portion 118 of pins 110 is retained in pin block 114. Pins 110 may generally be inserted into either end of connector shroud 106 and extend through pin block 114 for engagement with mating connector 101 (not shown in
Hood 108 generally protects pins 110 from damage or other interference by external objects or contaminants such as dirt, moisture, etc. Hood 108 generally extends beyond bend point 111, such that removal of hood 108 allows access to at least one row of pins 110. In particular, hood 108 may extend at least beyond a bend point 111d of a top row of pins 110d, thereby allowing bending tools to generally freely access pins 110d for bending during assembly of connection header 102. Hood 108 may generally be configured according to pins 110, such that hood 108 may advantageously be large enough to generally conceal pins 110 while minimizing the overall size of connection header 102. Hood 108 may be secured to an end of connector shroud 106 adjacent housing 104 by any method that is convenient. For example, as shown in
As shown in
Turning now to
At step 404, a plurality of pins are inserted into a connector shroud 106. For example, pins 110 may be inserted into connector shroud 106 to a predetermined distance. An expanded feature 124 of pins 110 may be provided to engage an interior surface of pin apertures 116, as described above. Apertures 116 may generally receive a first portion 118 of each pin 110. First portion 118 may remain parallel to pin apertures 116 after insertion.
At step 406 pins 110 are bent by row to form a second portion 120, which is generally orthogonal to first portion 118 of pins 110. Second portion 120 may thus extend downward toward PCB 154, as described above. Each row of straight pins may be bent by any known pin bending process. For example, in one embodiment a brace element is positioned adjacent pin 110 at a desired bending point, and a bend tool then manipulates second portion 120 downward such that it is generally orthogonal to first portion 118. As shown in
At step 408, pin sealant 122 may be applied adjacent pin apertures 116 of connector shroud 106. A semi-liquid sealant may be applied directly adjacent pin apertures 116 by an applicator nozzle. Pin sealant 122 may be hardened or cured. Preferably, an applicator nozzle is narrow to facilitate precise application of sealant about each aperture 116 within connector shroud 106. Pin sealant 122 may be applied to either side of pin block 114. Pin sealant 122 may advantageously provide a sealed interface between pins 110 and connector shroud 106 to generally prevent intrusion of contaminants such as a moisture, dirt, etc.
At step 410, hood 108 is secured to connector shroud 106. Hood 108 and shroud 106 may be provided with complimentary tongue and groove features, as described above, which provide a secure engagement therebetween. Further, a sealant or adhesive may be applied about a perimeter of hood 108 or shroud 106 to provide a sealed connection between hood 108 and shroud 106, thereby minimizing intrusion of moisture, dirt or other contaminants through an interface between hood 108 and shroud 106. As shown in the Figures, hood 108 may be secured to connector shroud 106 such that hood 108 extends beyond a bend point 111 of at least one pin 110. Hood 108 thus provides protection for pins 110 from external interference or contamination, and allows bending tools to access at least one pin 110 during assembly of header assembly 102.
At step 412, pin alignment guide 112 may be provided to align or support second portions 120 of pins 110. For example, as described above, apertures 134 may be provided in a base portion 136 of pin alignment guide 112 to generally prevent lateral displacement of pins 110. Accordingly, pin alignment guide 112 inhibits misalignment of pins 110 that may occur prior to assembly of connection header 102 to housing 104. Process 400 may then proceed to step 414.
At step 414, pin alignment guide 112 is secured to hood 108 and/or connector shroud 106. For example, as described above, lock arms 138 may be provided in pin alignment guide 112 to engage a detent 132 or other complementary feature in hood 108, as illustrated in the Figures. Process 400 may then proceed to step 416, which is optional. In embodiments not including step 416, process 400 may proceed directly to step 418.
At step 416, hood 108 may be secured to housing 104. As generally described above, complementary features such as a tongue 130′ and groove 128′ may be provided in housing 104 and hood 108, respectively, to provide a secure engagement therebetween. Further, a sealant or adhesive may be provided and applied about a perimeter of hood 108 adjacent housing 104, or vice versa. A sealant or glue may desirably seal an interface between hood 108 and housing 104 to prevent intrusion of contaminants such as dirt or moisture into an interface between hood 108 and housing 104. In embodiments where sealants are provided at each of the interfaces between connector shroud 106 and hood 108, between pin apertures 116 and pins 110, and also between hood 108 and housing 104, header assembly 102 provides a substantially sealed enclosure for pins 110 and other internal components of plug-in connector 100, thereby inhibiting intrusion of external contaminants such as moisture, dirt, etc.
At step 418, pin alignment guide 112 abuts a top surface of housing 104 to prevent pin alignment guide 112 from being displaced through aperture 156 toward housing 104, and especially from contacting PCB 154. For example, pin alignment guide 112 may be provided with features such as those described above, including but not limited to, an extension arm which rests upon a top surface of housing 104. Process 400 may then terminate.
Accordingly, connection header 102 provides a generally modular header assembly for a plug-in connector which is low in profile, relatively simple to manufacture and install, and resists damage to pins 110 despite exposure to vibration, shock, or external contaminants. Hood 108 and connector shroud 106 generally allow access to pins 110 during any bending process, while pin alignment guide 112 provides a convenient and easily installed alignment feature for pins 110.
Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The phrase “in one embodiment” in various places in the specification does not necessarily refer to the same embodiment each time it appears.
With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating certain embodiments, and should in no way be construed so as to limit the claimed invention.
Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.
All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.
This patent application is a continuation-in-part of U.S. patent application Ser. No. 11/496,682 filed on Jul. 31, 2006 U.S. Pat. No. 7,201,587, the complete disclosure of which is incorporated herein by reference in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 11496682 | Jul 2006 | US |
| Child | 11706535 | US |
