CN115151705A

CN115151705A - Method for manufacturing awning device

Info

Publication number: CN115151705A
Application number: CN202180016215.0A
Authority: CN
Inventors: J·P·梅恩斯特; S·R·A·凡霍特; M·G·索洛曼纽克; P·M·范斯蒂兰特
Original assignee: Renson Sunprotection Screens NV
Current assignee: Renson Sunprotection Screens NV
Priority date: 2020-06-05
Filing date: 2021-05-11
Publication date: 2022-10-04
Also published as: WO2021245481A1; EP4069932A1

Abstract

A method of manufacturing a canopy device, the canopy device comprising a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires, the power cable comprising one or more wires; an electrical coupling for coupling wires of an electrical supply cable to wires of a motor, the coupling comprising a male part and a female part, the male part and the female part being electrically and mechanically coupleable together, the male part comprising a Printed Circuit Board (PCB) having at least one printed conductor electrically coupled to at least one wire of a first one of the motor and the electrical supply cable, wherein the female part comprises a Printed Circuit Board (PCB) having at least one printed conductor electrically coupled to at least one wire of the other one of the motor and the electrical supply cable.

Description

Method for manufacturing awning device

Technical Field

The present invention relates to canopy devices, and more particularly to methods for manufacturing canopy devices having roll-up canopies.

Background

Canopy devices comprising a roll-up canopy are now usually electrically operable, wherein the canopy is rolled up or unrolled by the drive of an electric motor. The canopy is typically mounted in a steel shaft carrying the canopy.

It is not easy to install such canopy devices. In the rolled-up state, including the supports and the like, and together with a coaxially mounted motor (the assembly is known as a rucksack), the canopy must be inserted in a housing suspended from a wall (e.g. a facade). Furthermore, the motor must be connected to a power source, which may be mains voltage alternating current or photovoltaic generated low voltage direct current. The motor usually comprises a male or female part of the coupling, which, during insertion of the rucksack, the male or female part must be connected to the other (male or female) component to which the power supply is connected. Such a rucksack may weigh up to about 80kg and is therefore not easy to handle carefully.

Moreover, the connectors must be manipulated during the service life of these canopy devices. For example, if the canvas has to be replaced or if the motor is faulty, typically the entire canvas bag has to be removed from the housing with the male coupling member separated from the female coupling member.

An example of a suitable connector is given in EP 2354430 B1. A disadvantage of these connectors is the fragility of the connection prongs, which may be damaged before the insertion of the canvas bag into the housing, during handling of the component at the construction site, or which bend during the insertion of the canvas bag into the housing.

Disclosure of Invention

The object of the present invention is to make a canopy device with a roll-up canopy, which is equipped with connectors that are able to resist the forces that occur during insertion of the canvas bag and during which the connectors are coupled simultaneously. It is a further object to provide a connector which is not fragile when handled in the field.

According to a first aspect of the invention, a method for manufacturing an awning device is provided. The canopy device includes: a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires. The power supply cable includes one or more wires and an electrical coupling for coupling the wires of the power supply cable to the wires of the motor. The coupling comprises a male part and a female part that can be coupled together electrically and mechanically, the male component comprises a Printed Circuit Board (PCB) having at least one printed conductor, the at least one printed conductor is electrically coupled to at least one wire of a first one of the motor and the supply cable. The female component includes a Printed Circuit Board (PCB) having at least one printed conductor electrically coupled to at least one wire of the other of the motor and the supply cable. The method comprises steps A and/or B; the step A is as follows:

a1 providing a Printed Circuit Board (PCB) comprising at least one lip having at least one printed conductor thereon electrically coupled to at least one electric wire of a first one of the motor and the supply cable, or comprising at least one contact pin electrically coupled to at least one printed conductor on the printed circuit board electrically coupled to at least one electric wire of a first one of the motor and the supply cable;

a2: introducing the printed circuit board into a first housing and/or a mold, wherein at least one lip or one contact pin is located outside the housing and/or the mold;

filling the housing and/or the mould with a polymer, the housing and/or the mould comprising a printed circuit board;

step B comprises the following steps:

b1: providing a Printed Circuit Board (PCB) on which at least one electrically conductive contact object or at least one contact receptacle is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one wire of the other of the motor and the supply cable;

b2, introducing the printed circuit board into the first housing and/or the mould;

b3 filling the housing and/or the mold with a polymer, the housing and/or the mold containing a filled printed circuit board, wherein at least one contact object or contact receptacle remains accessible from outside the housing.

According to some embodiments, step a may be performed.

According to some embodiments, step A2 may comprise introducing the printed circuit board into a first mold, wherein at least one lip or one contact pin is located outside the mold.

According to some embodiments, step A2 may comprise introducing the printed circuit board into the first housing with at least one lip or one contact pin outside the housing.

According to some embodiments, step A2 may comprise providing the housing in the mould before the printed circuit board of step A1 is introduced into the mould.

According to some embodiments, the method may comprise a step A4, wherein the housing is closed by a closure.

According to some embodiments, step A1 may include providing a Printed Circuit Board (PCB) including at least one lip having at least one printed conductor thereon electrically coupled to at least one wire of a first one of the motor and the supply cable.

According to some embodiments, step A1 may include providing a Printed Circuit Board (PCB) including at least one contact pin electrically coupled to at least one printed conductor on the PCB, the at least one printed conductor being electrically coupled to at least one wire of a first one of the motor and the supply cable.

According to some embodiments, step B may be performed.

According to some embodiments, step B2 may comprise introducing the printed circuit board into a first mould, wherein at least one lip or one contact pin is located outside the mould.

According to some embodiments, step B2 may comprise introducing the printed circuit board into the first housing with at least one lip or one contact pin outside the housing.

According to some embodiments, step B2 may comprise providing the housing in the mould before the printed circuit board of step A1 is introduced into the mould.

According to some embodiments, the method may comprise step B4, wherein the housing is closed by a closure.

According to some embodiments, step B1 may include providing a Printed Circuit Board (PCB) including at least one conductive object coupled to at least one printed conductor on the PCB, the at least one printed conductor being electrically coupled to at least one wire of the other of the motor and the supply cable.

According to some embodiments, step B1 may comprise providing a Printed Circuit Board (PCB) comprising at least one electrical contact socket coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of the other of the motor and the supply cable.

According to some embodiments, steps a and B may be performed.

According to some embodiments, the filling may be with a thermoplastic polymer or an elastomeric polymer. Thus providing the polymer volume. Suitable polymers are all polymers which are suitable for accommodating electrical components, for example extrusion compatible compounds such as thermoplastics and elastomers. Preferably, the wall thickness and the polymer are selected to achieve a breakdown voltage of at least 600V. Typical suitable polymers are Polyamides (PA), polyesters (PES), polyolefins such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers and the like. More preferably PA or PVC is used.

According to a second aspect, a canopy device is provided. These canopy devices can be obtained using the method according to the first aspect of the invention. The awning device comprises a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires; a power supply cable comprising one or more wires; electrical coupling for coupling wires of a supply cable to wires of a motor, the electrical coupling comprising a male part and a female part which can be coupled together electrically and mechanically, characterized in that the male part comprises a Printed Circuit Board (PCB) comprising at least one lip on which at least one printed conductor is provided, the at least one printed conductor being electrically coupled to at least one wire of a first one of the electric motor and the supply cable, wherein the female part comprises a Printed Circuit Board (PCB) comprising at least one electrically conductive contact object coupled to the at least one printed conductor, the at least one printed conductor being electrically coupled to at least one wire of the other one of the motor and the supply cable.

The lip is a protruding part of the printed circuit board, also called a fin, which is located in the plane of the printed circuit board, protruding at the edge of the printed circuit board. The electrically conductive contact object on the female part is, for example, a spring contact or a sliding contact, which is intended to make electrical contact with a printed conductor on one or more lips of the male part. These conductive contact objects are preferably located at the edge of the printed circuit board of the female component. They may be made, for example, of beryllium copper (e.g., containing about 1.7% to 1.9% beryllium). In some cases, they may also be coated with a thin layer of gold.

The wires are electrically conductive wires or cores (typically copper wires or cores) that conduct current to and from the motor (e.g., low voltage direct current of 24V or 48V, or alternating current of 3A to 4A and 230V) as necessary.

The printed circuit board includes printed conductors on the board. The board is typically made of epoxy resin, for example glass fibre textile (e.g. fabric) reinforced epoxy resin, and has a thickness in the range of 1.0mm to 2.0mm, for example 1.6 mm.

The printed conductor is an electrical conductor. The use of printed circuit boards for high voltage alternating current imposes high requirements and preferably requires suitable dimensions. Of course, in the case of high current of high voltage alternating current, the weight per surface area of the conductor is 0.5 ounces per square foot to 3 ounces per square foot, for example, between 1 ounce per square foot and 2 ounces per square foot (inclusive), in order to be able to conduct sufficient current. Of course, for a conductor having a surface area weight of 2 ounces per square foot, the cross-section is preferably equal to or greater than 0.106mm ² 。

The printed conductor is made of an electrically conductive material, typically a metal and preferably copper or a copper alloy. In some cases, the printed conductors may be coated with solder, nickel or gold, or may be treated with mercaptobenzimidazole to prevent corrosion. In some cases, the printed conductors are "conformally coated", to prevent corrosion due to condensation current leakage and/or reduced lifetime. This can be done by dipping, spraying or vacuum depositing silicone rubber, polyurethane, acrylic or epoxy.

Printed conductors on one or more lips of the printed circuit board are preferably used for good electrical conductivity, but are also corrosion resistant. They may be made, for example, from beryllium copper (e.g., containing about 1.7% to 1.9% beryllium). In some cases, the conductor may also be coated with a thin layer of gold.

The canopy device typically also includes a device housing for housing the rotatable canopy and the motor.

According to some embodiments, the male component may comprise a housing surrounding the printed circuit board, and/or the female component may comprise a housing surrounding the printed circuit board.

The shell of the male connector may protrude beyond the one or more lips. Obviously, the lip or lips are free on the outside of the shell so that they can come into contact with the contact object of the female part.

According to some embodiments, the male component may comprise a housing enclosing the printed circuit board. According to some embodiments, the female component may include a housing that surrounds the printed circuit board.

The housing of the female connector may protrude beyond the contact object. It is clear that the contact objects are free so that they can come into contact with one or more lips of the male part.

According to some embodiments, each of the housings may comprise an outer shell providing, or entirely, an outer side of the housing and enclosing the printed circuit board, wherein the printed circuit board in the outer shell is enclosed by a polymer volume that fills the outer shell except for one or more lips of the male part and the electrically conductive contact objects of the female part.

The printed circuit board is thus completely encapsulated by the polymer. The printed circuit board is thus embedded in the polymer. I.e. in addition to the one or more lips of the male part and the electrically conductive contact object of the female part.

The outer shell provides at least a portion of the outer wall and preferably all of the outer wall for each shell. This housing, which may be composed of different parts, may be produced in very precise dimensions (e.g. by injection moulding the whole or parts of the housing). The electrical components (for example, the printed circuit board accommodated in this housing) are therefore surrounded by a wall, the thickness of which can be ensured very precisely. Thus, a minimum distance between the outer wall of the housing and each of the components present in the outer shell can be ensured. The minimum thickness of the housing is preferably between 0.5mm and 2 mm. Preferably, an outer envelope is provided having a breakdown voltage of 31kV/mm between the two sides of the wall. The insulation must conform to a base insulation of 1250V, measured according to EN 60355.

The polymer volume may be poured or cast into a mold or, in the case of a housing, into a housing, which may or may not be carried by the mold, with the printed circuit board being located at a desired position within the mold or housing. Thus, the printed circuit board may be completely encased and surrounded such that no electrical components on the printed circuit board are located outside the polymer volume, i.e. outside the housing, except for the lip(s) or the electrically conductive contact object(s). This creates a polymer volume. The polymer volume contacts the printed circuit board over its entire surface area, except for the lip(s) or the conductive contact object(s).

Suitable polymers for the housing are all polymers suitable for accommodating electrical components, for example compatible polymers such as thermoplastics and elastomers. Preferably, the wall thickness and the polymer are selected to achieve a breakdown voltage of at least 600V. Typical suitable polymers are Polyamides (PA), polyesters (PES), polyolefins such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers and the like. More preferably PA or PVC is used.

Suitable polymers of the polymer volume are all polymers suitable for electrical component contact, preferably injection moldable polymers such as thermoplastics and elastomers. For example, these polymers are Polyamides (PA), polyesters (PES), polyolefins such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers and the like. More preferably, PA or PVC is used, preferably applied by injection moulding.

The polymer used for the shell and the polymer used for the polymer volume must be complementary and adhere to each other.

According to other embodiments, the male part and/or the female part may comprise a housing consisting of only a shell. The casing may be composed of different parts, which are attached and adhered to each other by a closing system (for example, by a snap system). After the different parts of the housing are mounted and attached (e.g., snapped closed), the printed circuit board is completely enclosed by the housing, except for one or more lips on the male component. For the female part, a free opening is left in the closed shell, which allows the lip to make contact with an electrically conductive contact object located in the housing.

The housing or housing part is preferably made of a polymer, more particularly an injection moulded polymer. The electrical components (for example, the printed circuit board accommodated in this housing) are therefore surrounded by a wall whose thickness can be ensured very precisely. Thus, a minimum distance between the outer wall of the housing and each of the components present in the outer shell can be ensured. The minimum thickness of the housing is preferably between 0.5mm and 2 mm. Preferably, an outer envelope is provided having a breakdown voltage of 31kV/mm between the two sides of the wall. The insulation must conform to a base insulation of 1250V, measured according to EN 60355.

Suitable polymers are all polymers suitable for the contacting of electrical components, preferably injection-moldable polymers, such as thermoplastics and elastomers. For example, these polymers are Polyamides (PA), polyesters (PES), polyolefins (e.g., polypropylene (PP), polyethylene (PE)), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers, and the like. More preferably, PA or PVC is used, preferably by injection moulding coating.

According to other embodiments, the male part and/or the female part may comprise a housing consisting of only a shell. The housing may be composed of different parts that are in contact and attached to each other by a closing system, such as a snap system. After the different parts of the housing are mounted and attached (e.g. snapped closed), the printed circuit board is completely enclosed by the housing. For the male part only one or more lips remain free. For the female part, an opening is provided to allow a later inserted lip of the male part to make electrical contact with the contacting object.

According to other embodiments, the male part and/or the female part may comprise a housing formed completely around the printed circuit board (by overmolding the printed circuit board with a polymer in the form of a final housing). The printed circuit board and the associated components are clamped in a mould, wherein the contact pins and/or the contact sockets remain free in order to later allow electrical contact, and this mould is filled with a polymer by injection moulding. For the male component, only one or more lips remain free. For the female part, an opening is provided to allow the later inserted lip of the male part to come into contact with the contact object. Possible polymers are those stated above. Preferably, PA and PVC are used. The printed circuit board is thus completely embedded in the housing, only the contact pins and/or the contact sockets remaining free. The minimum thickness of the shell is preferably between 0.5mm and 2 mm.

According to other embodiments, the male part and/or the female part may comprise a housing which partly consists of a shell and partly is formed by overmolding the printed circuit board with a polymer in the form of a final housing. Possible polymers are those stated above. Preferably, PA and PVC are used. The minimum thickness of the shell is preferably between 0.5mm and 2 mm.

According to some embodiments, the male part and the female part may be adapted for coupling at least one housing, if necessary two shells, and comprises a handling element that handles the movement of the male and female parts during coupling thereof in the coupling direction.

The handling element may determine a relative movement of the male part and the female part such that the one or more lips of the male part and the respective associated contact object of the female part are correctly oriented to each other during coupling.

The male part may have protruding elements on the housing which may be inserted into openings in the housing of the female part during coupling. Alternatively, the female part may have a protruding element on the housing, these protruding elements can be inserted during coupling in an opening in the housing of the male part. The protruding element protrudes from the housing in the direction of movement (i.e. in the coupling direction) during coupling. The opening may be conical in order to thus manipulate such movement.

In some embodiments, the opening in the female part behind which the electrically conductive contact object is located is also designed conically or with walls, the mutual distance between which is smaller closer to the contact object, so that upon insertion of the corresponding lip of the male part, the movement of the lip is steered towards the electrically conductive contact object. The lip may also be rounded at the front, in order to manipulate the movement of the lip into the opening.

According to some embodiments:

the male part may have one or more projections in the coupling direction and the female part may have one or more recesses corresponding to the projections in the coupling direction; and/or

The female part may have one or more protrusions in the coupling direction, and the male part may have one or more recesses corresponding to the protrusions in the coupling direction.

It has to be stated that the operating element forms an integral part of the one or more housings. The operating element may take a number of forms, for example a projecting portion of the housing of one of these components that slides over a thinner region of the housing of the other component. The handling element moves, handles and assists or guides the two parts correctly towards each other by e.g. protrusions, ribs or the like fitting in grooves or the like, or conical surfaces meeting each other. The actuation element can center the two components relative to one another. Here, the aim is to position the electrical coupling portions of the male and female parts correctly relative to each other before the electrical coupling begins. It is therefore important that the actuating elements first come into contact with each other and actuate each other before electrical contact is made between the male part and the female part.

According to some embodiments, at least one of the handling elements of one of the parts may be in contact with a corresponding handling element of the other part in the coupling direction before one or more printed conductors on one or more lips of the male part can make electrical contact with a corresponding contact object of the female part.

In other words, at least one of the steering elements of one of these components protrudes further from the housing of this component in the coupling direction than the furthest point of the one or more printed conductors on one or more lips or contact objects of this component. This is advantageous in that the handling or guiding member ensures that the insertion of the one or more printed conductors on the one or more lips into or onto the corresponding contact object takes place smoothly with the smallest possible dimensional deviations before electrical coupling, as a result of which the service life of the lips or the conductors and the contact object can be extended.

According to some embodiments, a sealing ring may be provided for watertight contact between the housings of the male and female parts.

According to some embodiments, the sealing ring may be positioned around at least one lip of the male component.

In case there are several lips, each of the lips may be individually surrounded by a ring.

The sealing ring may be seated in or on the housing of the male component and describes the location where the lip protrudes through the housing.

According to some embodiments, the sealing ring may be placed around an opening where a lip of the male component is guided through a housing of the female component for making electrical contact between a conductor on the lip and a contact object of the female component.

In the case where there are several openings, each of the openings may be individually surrounded by a ring.

The sealing ring may be seated in or on a housing of the female part, wherein an opening is provided in the housing for the passage of the one or more lips.

According to some embodiments, the sealing ring may be disposed at the base of the wall surrounding the lip. It may be sufficient that one sealing ring surrounds the wall base.

According to some embodiments, the sealing ring may be provided at the top of an opening through which the lip can be inserted. A sealing ring on this top may suffice, wherein perhaps the top is provided with a holder for holding the ring.

According to some embodiments, one of the wires of the motor and one of the wires of the power supply cable may be a ground conductor.

According to some embodiments, the male part and the female part may be adapted to be coupled in the coupling direction, and during the coupling in the coupling direction, the printed electrical conductor or the contact object coupled to the lip of the ground conductor of the supply cable is brought into contact with the corresponding contact object or the printed electrical conductor coupled to the lip of the ground conductor of the motor before one or more other printed electrical conductors on the one or more lips of the male part may be brought into electrical contact with the corresponding contact object of the female part.

Establishing a ground connection first is often important to avoid short circuits and the like and to ensure the safety of the coupling.

The printed electrical conductor coupled to the lip of the ground conductor may be designed to be more robust than other printed conductors coupled to the current carrying wire. For example, they may be designed thicker or wider. As are the printed conductors on the printed circuit board of the female component. The contact object coupled to the ground conductor may also be designed to be stronger, e.g. thicker, or multiple contact objects may be provided to contact the same ground conductor on the corresponding lip.

Advantageously, during the coupling of these components, the order in which the different parts come into contact is that which ensures firstly the handling of the components, secondly the electrical coupling of the ground conductor and only thereafter the coupling of the conductor carrying the current.

Thus, in accordance with a preferred embodiment, there is provided a canopy device

Wherein the male part and the female part are adapted to be coupled in a coupling direction and during coupling in the coupling direction the printed electrical conductor or contact object coupled to the lip of the ground conductor of the supply cable is in contact with the corresponding contact object or printed electrical conductor coupled to the lip of the ground conductor of the motor before one or more other printed electrical conductors on the one or more lips of the male part can be in electrical contact with the corresponding contact object of the female part;

wherein the male part comprises a housing enclosing the printed circuit board, and wherein the female part comprises a housing enclosing the printed circuit board, and wherein at least one housing (where applicable both housings) contains a handling element which handles the movement of the male part and the female part during coupling of the male part and the female part in the coupling direction, at least one of the handling elements of one of the parts being in contact with a corresponding handling element of the other part in the coupling direction before one or more printed conductors on one or more lips of the male part can make electrical contact with a corresponding contact object of the female part.

According to some embodiments, the supply cable may comprise M1 wires, the male or female part comprising N1 printed conductors or conductive contact objects on one or more lips, wherein N1> = M1 and M1> =2.

According to some embodiments, the motor may comprise M2 wires, the male or female component comprising N2 printed conductors or conductive contact objects on one or more lips, wherein N2> = M2 and M2> =2.

According to some embodiments, it is possible that M1= M2 and N1> M1 or N2> M2.

In one embodiment, M1= M2> =3 and both N1 and N2 are greater than 3, e.g., M1= M2= N1= N2=4.

In some embodiments, the male or female component coupled to the power cable is configured such that it is compatible with a female or male component coupled to a motor mounted to the left or right side relative to the rotating canopy. Canopy devices are typically designed in two forms, where the motor can be located either to the left or to the right of the roll-up canopy. When using the same motor, depending on whether the male or female connector is coupled to the motor, printed conductors or conductive contact objects on one or more lips may be mirrored depending on whether left or right side installation. In order to provide the possibility of using the same component (male or female) on the supply cable for both cases, it is necessary to arrange symmetrically on the component coupled to the supply cable printed conductors or electrically conductive contact objects on one or more lips. Thus, for example, in the case of M conductors in a power supply cable, a single wire may be electrically coupled to two printed conductors or conductive contact objects on one or more lips, both conductors being integrated in the same male or female part as a mirror image of each other.

In other embodiments, the printed conductors or conductive contact objects on one lip that are coupled to the ground conductors are arranged centrally, and therefore need not be duplicated, while the other printed conductors or conductive contact objects of the one or more lips that conduct current are duplicated and arranged symmetrically.

According to some embodiments, the wires may be coupled to the printed conductors by a griplet connector. The griplet connector may for example be made of copper, in some cases with a nickel or nickel-tin coating.

In alternate embodiments, the wire may also be soldered to the printed conductor, a crimped contact may be used, or the wire may be coupled to the printed conductor using any known technique.

The griplet connector or other connector used is preferably embedded in a polymer volume containing the printed circuit board.

According to some embodiments, the male component may be coupled to wires of a power supply cable, and the female component may be coupled to wires of a motor.

According to some embodiments, the female component may be coupled to wires of a power supply cable, and the male component may be coupled to wires of a motor.

In some embodiments, each lip, for example four lips, may carry one printed conductor. In other embodiments, one, some, or all of the lips comprise more than one printed conductor printed adjacent to each other on the lips.

According to some embodiments, the printed conductors may be printed in pairs next to each other on one lip.

According to a third aspect, a method is provided for installing the canopy device according to the second aspect of the invention. The method for installing a canopy device according to the second aspect of the invention comprises a device housing, wherein the method comprises inserting the motor and the roll-up canopy laterally into the device housing, and effecting coupling of the male and female parts of the coupling during this insertion.

The motor and roll-up canopy (collectively known as a canvas bag) may be inserted into the device housing from the front, in some cases the device housing itself is mounted on the wall to which the canopy device is to be attached. The component attached to the supply cable may already be present in the housing, supported by the mounting of the housing. Thus, during insertion of the rucksack, while coupling of the male part to the female part is achieved. After the supply cable is inserted and thus coupled to the motor, the housing is closed with a closure.

According to a fourth aspect, a method for manufacturing a canopy device is provided. The method for manufacturing the canopy device according to the first aspect of the invention comprises steps a and/or B, step a being

A1: providing a Printed Circuit Board (PCB) comprising at least one lip having at least one printed conductor thereon electrically coupled to at least one wire of a first one of the motor and the supply cable.

A2, introducing the printed circuit board into a first mould, wherein at least one lip is positioned at the outer side of the mould;

a3, filling a mould containing the printed circuit board with polymer;

the step B is as follows:

providing a Printed Circuit Board (PCB) on which at least one electrically conductive contact object is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one wire of the other of the motor and the supply cable;

b2: introducing a printed circuit board into a first mold;

filling a mold with a polymer, the mold comprising a printed circuit board, wherein at least one contact object remains accessible from outside the housing.

According to some embodiments, steps a and B may be performed.

According to some embodiments, the method comprises the steps of: before the printed circuit board according to step A1 or B1 is introduced into the mould, the housing is provided in the mould, and then in step A4 or B4 the housing can be closed by a closure member. According to other embodiments of step A2 or B2, the printed circuit board is placed directly in the housing, rather than in the mold. The housing is filled and then in step A4 the housing can be closed by a closure.

The housing may be made in one piece, for example, the housing may be closed around a volume, which may contain a printed circuit board, and in which the housing is provided with openings for the lips, or left open so that contact objects remain accessible for contact with the lips. Or the housing may be comprised of at least a portion of the enclosed volume and a closure member for closing the housing. Or the housing may be made up of several parts which together may enclose a volume. Preferably, the housing or part of the housing is injection moulded.

The printed circuit board may be held in place by auxiliary means during the introduction of the polymer, or the mould or housing may have a supporting and/or clamping face on which the printed circuit board is clamped or rests.

The mould or housing may also comprise an inlet for the electrical wires or the entire supply cable, through which the electrical wires reach the printed circuit board in the volume.

The mold or housing containing the printed circuit board may be filled with a polymer by injection molding.

Preferably, the mold or housing is filled with a polymer suitable for contacting the electrical component, preferably an injection moldable polymer such as thermoplastics and elastomers. For example, these polymers are Polyamides (PA), polyesters (PES), polyolefins such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers and the like. More preferably, PA or PVC is used, preferably coated by injection moulding.

According to a fifth aspect, a canopy device is also provided. The canopy device may be obtained by a method according to the first or fourth aspect of the invention.

According to a sixth aspect, a canopy device is also provided. The canopy device includes: a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires; a power supply cable comprising one or more wires; electrical coupling for coupling the wires of an electrical supply cable to the wires of a motor, the coupling comprising a male part and a female part that can be coupled together electrically and mechanically, characterized in that:

the male component comprising a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of a first one of the motor and the supply cable, the male component comprising a housing enclosing the printed circuit board and providing at least one coupleable electrical connector; and/or

The female component includes a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board that is electrically coupled to at least one electrical wire of the other of the motor and the supply cable, includes a housing that encloses the printed circuit board, and provides at least one coupleable electrical connector.

In accordance with some embodiments of the present invention,

the male component comprises a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of a first one of the motor and the supply cable, the male component comprising a housing enclosing the printed circuit board and providing at least one coupleable electrical connector; and

the female part comprises a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of the other one of the motor and the supply cable, the female part comprising a housing enclosing the printed circuit board and providing at least one coupleable electrical connector.

According to some embodiments, the printed circuit board of the male part and/or the female part in the housing may be enclosed by a polymer volume filling the enclosure.

According to some embodiments, the at least one electrical connector of the male component may be a printed conductor.

According to some embodiments, the at least one electrical connector of the female component may be a spring contact or a sliding contact.

According to a seventh aspect, a canopy device is provided. These canopy devices can be manufactured using the method according to the first aspect of the invention. The canopy device according to the seventh aspect comprises a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires; a power supply cable comprising one or more wires; electrical connector for coupling electric wires of an electric supply cable to electric wires of a motor, the connector comprising a male part and a female part which can be coupled together electrically and mechanically, wherein the male part comprises at least one contact pin and the female part comprises at least one contact socket, characterized in that: the male component includes a Printed Circuit Board (PCB) with at least one contact pin on the PCB electrically coupled to at least one printed conductor on the printed circuit board that is electrically coupled to at least one wire of a first one of the motor and the supply cable, wherein the female component includes a Printed Circuit Board (PCB) with at least one contact receptacle electrically coupled to at least one printed conductor on the printed circuit board that is electrically coupled to at least one wire of the other one of the motor and the supply cable. The male part comprises a housing enclosing the printed circuit board and/or the female part comprises a housing enclosing the printed circuit board.

The canopy device typically also includes a device housing for housing the rotatable canopy and motor.

According to some embodiments, the male component may comprise a housing enclosing the printed circuit board.

According to some embodiments, the female component may include a housing that surrounds the printed circuit board.

Furthermore, the contact pins and the sockets remain accessible, so that a coupling is produced between the male part and the female part.

The housing of the female connector may protrude beyond the contact receptacle. The housing of the male connector may protrude beyond the contact pins.

According to some embodiments, each of the shells may comprise an outer shell provided partially or entirely outside the shell and enclosing the printed circuit board, wherein the printed circuit board in the outer shell is enclosed by a polymer volume filling the outer shell.

The printed circuit board is thus completely encapsulated by the polymer. The printed circuit board is thus embedded in the polymer.

According to other embodiments, the male part and/or the female part may comprise a housing consisting of only a shell. The casing may consist of different parts that are attached and adhered to each other by a closing system, for example a snap system. After the different parts of the housing are mounted and attached, e.g. snapped closed, the printed circuit board is completely enclosed by the housing.

According to some embodiments, the male part and the female part may be adapted to be coupled to at least one housing, in this case two housings, in the coupling direction and comprise a handling element which handles the movement of the male part and the female part during the coupling of the male part and the female part in the coupling direction.

The handling element may determine a relative movement of the male part and the female part such that the contact pins of the male part and the corresponding associated contact sockets of the female part are correctly oriented with respect to each other during coupling.

The male part may have a protruding element on the housing, which protruding element may be inserted into an opening in the housing of the female part during coupling. Alternatively, the female part may have a protruding element on the housing, which protruding element may be inserted into an opening in the housing of the male part during coupling. The projecting element projects from the housing in the direction of movement during coupling, i.e. in the coupling direction. The opening may be conical, such that the movement is handled thereby.

According to some embodiments, at least one of the handling elements of one of the parts may be brought into contact with a corresponding handling element of the other part in the coupling direction before one or more contact pins of the male part can be brought into electrical contact with corresponding contact sockets of the female part.

In other words, at least one of the operating elements of one of the components protrudes further from the housing of the component in the coupling direction than the furthest point of the contact pin or contact socket of this component. This is advantageous because the electrically coupling of the handling or guiding means ensures that the insertion of the contact pins in the corresponding contact sockets takes place smoothly with the smallest possible dimensional deviations, as a result of which the service life of the contact pins and the contact sockets can be prolonged and bending of the contact pins can be reduced or even prevented.

According to some embodiments, one of the wires of the motor and one of the wires of the supply cable may be a ground conductor.

According to some embodiments, the male part and the female part may be adapted to be coupled in a coupling direction, and during coupling in the coupling direction, the contact pin or the contact socket coupled to the ground conductor of the power supply cable comes into contact with the corresponding contact socket or the contact pin coupled to the ground conductor of the motor before one or more other contact pins of the male part are able to make electrical contact with the corresponding contact socket of the female part.

Establishing a connection to ground first is often important to avoid short circuits and the like and to ensure the safety of the coupling.

The contact pins and contact sockets coupled to the ground conductors may be designed to be more robust than the contact pins and contact sockets coupled to the current carrying wires. For example, they may be designed thicker. The contact pins coupled to ground, and/or the contact sockets coupled to ground may, for example, be designed longer and/or placed in a position projecting further above the printed circuit board. In all cases, this ensures that these contact pins and contact sockets come into contact first before the other contact pins and contact sockets are electrically coupled.

Advantageously, the order in which the different parts come into contact during the joining of these components is the order in which the handling of the components is first ensured, then the electrical coupling of the ground conductors is ensured and only then the joining of the conductors carrying the current.

Wherein one of the electric wires of the motor and one of the electric wires of the power supply cable is a ground conductor, the male part and the female part are adapted to be coupled in a coupling direction, and during coupling in the coupling direction, the contact pin coupled to the ground conductor of the power supply cable comes into contact with the corresponding contact socket coupled to the ground conductor of the other part before one or more other contact pins of the male part can come into electrical contact with the corresponding contact socket of the female part;

wherein the male part comprises a housing enclosing the printed circuit board, and wherein the female part comprises a housing enclosing the printed circuit board, and wherein at least one housing, both housings containing, where applicable, handling elements, which handle the movement of the male part and the female part during coupling of the male part and the female part in the coupling direction, at least one of the handling elements of one of these parts being brought into contact with a corresponding handling element of the other part in the coupling direction before the one or more contact pins of the male part can make electrical contact with corresponding contact receptacles of the female part.

According to some embodiments, the at least one contact pin may be axially surrounded by an electrically isolating wall, wherein there is no contact between the pin and the wall.

The minimum thickness of the partition wall is preferably between 0.5mm and 2 mm.

According to some embodiments, the at least one contact receptacle may be axially surrounded by an electrically isolating wall, wherein contact is made between the receptacle and the wall along the axis of the receptacle.

According to some embodiments, the at least one contact pin may be axially surrounded by an electrically isolating wall, wherein there is no contact between the pin and this wall, and wherein the at least one contact socket may be axially surrounded by an electrically isolating wall, wherein there is contact between the socket and this socket wall along the axis of the socket, and wherein the socket wall fits between the contact pin and the wall surrounding the contact pin.

The electrically isolating wall and the receptacle wall may be made of the same material as the outer shell of the housing and preferably form part of the component housing, for example part of the outer shell of the component housing. PA and PVC are preferred.

The material of the wall and/or the socket wall is electrically isolated if a breakdown voltage of at least 600 volts/mm, preferably more than 10 volts/mm, for example more than 30 volts/mm, is obtained.

The minimum thickness of the wall and/or the socket wall is preferably in the range of 0.5mm to 2 mm. Preferably, the wall projects in the axial direction along the contact pin, slightly further in the axial direction than the contact pin. It is also preferred that the socket wall projects in the axial direction along the contact socket, slightly further in the axial direction than the contact socket.

During coupling of the male and female parts, these walls also act in part as handling elements on the male and female parts.

The circumference of the radial cross section of these walls need not be the same shape as the radial cross section of the contact pin or the contact socket. The perimeter of the radial cross-section of the walls may be circular, oval, rectangular, square or the like.

According to some embodiments, a sealing ring may be provided for making a watertight contact between the wall surrounding the contact pin and the socket wall.

According to some embodiments, this sealing ring may be provided at the base of the wall surrounding the contact pin. A sealing ring surrounding the base may be sufficient.

According to some embodiments, this sealing ring may be provided at the top of the socket wall. A sealing ring on this top may suffice, wherein perhaps the top is provided with a holder for holding the ring.

According to some embodiments, the supply cable may comprise M1 wires, the male part or the female part comprising N1 contact pins or contact sockets, wherein N1> = M1 and M1> =2.

According to some embodiments, the motor may comprise M2 wires, the male part or the female part comprising N2 contact pins or contact sockets, wherein N2> = M2 and M2> =2.

In accordance with some embodiments of the present invention, it may be M1= M2 and N1> M1 or N2> M2.

In some embodiments, the male or female component coupled to the supply cable is configured such that it is compatible with a female or male component coupled to a motor mounted on the left or right side relative to the rotating canopy. Canopy devices are typically designed in two forms, where the motor can be positioned to the left or right of the roll-up canopy. When the same motor is used, depending on whether the male or female connector is coupled to the motor, the contact pins or contact sockets may be mirror-positioned depending on whether left-side or right-side mounting is used. In order to provide both cases for the possibility of using the same component (male or female) on the energizing cable, the contact pins and the contact sockets must be arranged symmetrically on the component coupled to the energizing cable. Thus, for example, in the case of M wires in a supply cable, a single wire may be electrically coupled to two contact pins or contact sockets, both integrated in the same male or female part as a mirror image of each other.

In other embodiments, the contact pin and the contact socket coupled to the ground conductor are arranged centrally and therefore do not need to be duplicated, while the other contact pins or contact sockets conducting the current are duplicated and symmetrically arranged.

The contact pins and contact sockets are not limited in size, but the length of the pins and the depth of the sockets are preferably between 8mm and 15 mm. The cross-sectional area of the contact pin and thus of the contact socket is preferably 2.4mm ² And 5mm ² In the meantime. For contact pins and contact sockets having a circular cross-section this means that the diameter of the cross-section preferably varies between 1mm and 2mm, including the instant number. Preferably, but not necessarily, the pin and socket are cylindrical in cross-section. The cross-section may also be, for example, rectangular, polygonal or elliptical. Although relatively small in size, the prongs and sockets should be robust in that they are subjected to relatively large forces during installation of the canvas bag.

The contact pins and contact sockets are also electrically conductive and are preferably made of copper or copper alloy, in some cases with a hard gold coating of several tens of micrometers (e.g. 50 μm) of gold on a nickel buffer layer coated onto the copper.

According to some embodiments, the wires may be coupled to the printed conductors by a griplet connector. The griplet connector may be made of copper, for example, with a nickel or nickel-tin coating in some cases.

In alternative embodiments, the wire may also be soldered to the printed conductor, a crimped contact may be used, or the wire may be coupled to the printed conductor using any known technique.

According to some embodiments, the female component may be coupled to the wires of the supply cable and the male component may be coupled to the wires of the motor.

According to an eighth aspect, a method is provided for installing a canopy device according to the seventh aspect of the invention. A method for installing a canopy device according to the seventh aspect of the invention comprises providing a canopy device according to the seventh aspect of the invention, the canopy device comprising an apparatus housing. The method includes inserting the motor and the roll-up canopy into the device housing, wherein during insertion, coupling of the male and female components of the coupling is achieved.

The motor and roll-up canopy (collectively known as a sail cloth bag) may be inserted into the device housing from the front, in some cases the device housing itself is mounted on the wall to which the canopy apparatus is to be attached. The component attached to the supply cable may already be present in the housing, supported by the mounting of the housing. Thus, during insertion of the canvas bag, coupling of the male element with the female element is simultaneously achieved. After the supply cable is inserted and thus coupled to the motor, the housing is closed with a closure.

According to a ninth aspect, a method for manufacturing an awning device is provided. A method for manufacturing an awning device according to a ninth aspect of the invention comprises steps a and/or B, step a being:

a1 providing a Printed Circuit Board (PCB) on which at least one contact pin is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one wire of a first one of the motor and the supply cable;

a2, introducing the printed circuit board into a first mould;

filling a mold with a polymer, the mold comprising a printed circuit board;

the step B is as follows:

providing a Printed Circuit Board (PCB) on which at least one contact receptacle is coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one wire of the other of the motor and the supply cable;

b2, introducing the printed circuit board into a first mould;

b3 filling a mold with a polymer, the mold comprising a printed circuit board.

According to some embodiments, steps a and B may be performed.

According to some embodiments, the method comprises the step of providing the housing in the mould before introducing the printed circuit board from step A1 or B1 into the mould, and then in step A4 or B4 the housing can be closed by the closure member. According to other embodiments of step A2 or B2, the printed circuit board is placed directly in the housing, instead of in the mould. The housing is then filled, after which the housing can be closed by a closure in step A4.

The housing may be made of one piece, for example, the housing may be closed around a volume, which may contain a printed circuit board, and in which housing openings are provided for the contact pins or sockets. Or the housing may comprise at least one portion of the surrounding volume and a closure for closing the housing. Or the housing may be made up of several parts which together may enclose a volume. Preferably, the housing or parts of the housing are injection moulded.

The mould and/or the housing may also comprise an inlet for the electric wires or the entire supply cable, through which the electric wires reach the printed circuit board in the volume.

The mould or housing provided with the printed circuit board may be filled with a polymer by injection moulding.

Preferably, the mold or housing is filled with a polymer suitable for contacting the electronic component, preferably an injection moldable polymer such as thermoplastics and elastomers. For example, these polymers are Polyamides (PA), polyesters (PES), polyolefins such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and similar or mixed polymers, in some cases supplemented with softeners, flame retardants, fillers and the like. More preferably, PA or PVC is used, preferably applied by injection moulding.

According to a tenth aspect, there is also provided a canopy device. May be achieved by the first aspect or according to the invention the method of the ninth aspect obtains an awning device.

The canopy device includes: a roll-up canopy; an electric motor for rotating the roll-up canopy, the motor being powered by one or more wires; a power supply cable comprising one or more wires; electrical coupling for coupling the wires of an electrical supply cable to the wires of a motor, the electrical coupling comprising a male part and a female part that can be electrically and mechanically coupled together, characterized in that:

the male component comprises a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of a first one of the motor and the supply cable, the male component comprising a housing enclosing the printed circuit board and providing at least one coupleable electrical connector; and/or

The female part comprises a Printed Circuit Board (PCB) on which at least one electrical connector is electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electrical wire of the other of the motor and the power supply cable, the female part comprising a housing enclosing said printed circuit board and providing at least one coupleable electrical connector.

In accordance with some embodiments of the present invention,

According to some embodiments, the printed circuit board of the male part and/or the female part in the housing may be enclosed by a polymer volume filling the housing.

According to some embodiments, the at least one electrical connector of the male component may be a contact pin.

In accordance with some embodiments of the present invention, the at least one electrical connector of the female part may be a contact receptacle.

Features and/or elements of embodiments of one aspect of the invention may be combined with features and/or elements of other aspects as long as they are not technically incompatible.

The independent and dependent claims present specific and preferred features of embodiments of the invention. The features of the dependent claims may be combined with the features of the independent claims and the dependent claims or with the features as described hereinbefore and/or hereinafter in any suitable manner apparent to those skilled in the art.

The above and other features, characteristics and advantages of the present invention will be explained in some cases with reference to the following exemplary embodiments, in conjunction with the accompanying drawings.

The description of the exemplary embodiments is given by way of illustration and is not intended to limit the scope of the invention. Reference is made to the attached drawings in the following description. The same reference numbers in different drawings identify the same or equivalent elements.

Drawings

In order to give a more detailed description of the features of the invention, several preferred embodiments are described below, by way of non-limiting example, with reference to the accompanying drawings, in which:

fig. 1 schematically shows a canopy device according to the invention.

Fig. 2 and 3 schematically show parts of a male part and a female part, respectively, forming part of a canopy device according to the invention.

Fig. 4 schematically shows a male part and a female part forming part of a canopy device according to the invention.

Fig. 5 schematically illustrates how the ground conductors make electrical contact first during coupling of the male and female components, according to some embodiments of the invention.

Fig. 6 schematically shows parts of a housing of a male part and a female part forming part of a canopy device according to the invention.

Fig. 7 schematically shows a concave part forming part of the canopy device according to the invention, which concave part is symmetrically arranged.

Fig. 8 schematically shows a canopy device according to the invention.

Fig. 9 and 10 schematically show parts of a male part and a female part, respectively, forming part of a canopy device according to the invention.

Fig. 11 schematically shows a male part and a female part forming part of an awning device according to the invention.

Fig. 12a and 12b schematically illustrate how the ground conductors are first electrically contacted during coupling of the male and female components, according to some embodiments of the invention.

Fig. 13 schematically shows part of a housing of a female part forming part of a canopy device according to the invention.

Fig. 14 schematically shows a female part forming part of a canopy device according to the invention, which female part is symmetrically arranged.

Detailed Description

The invention is described below with reference to specific embodiments.

It is to be understood that although embodiments in accordance with the present invention and/or materials used to obtain embodiments have been discussed, various modifications or adaptations may be made without departing from the functional scope and/or spirit of the present invention. The invention is in no way limited to the embodiments described above, but may be implemented according to different variants without departing from the scope of the invention.

An awning device 100 according to the invention is shown in fig. 1; the details of the electrical coupling are shown in figures 2 and 3. The canopy device 100 according to the invention comprises a roll-up canopy 101 and an electric motor 102 for rotating the roll-up canopy. The motor 102 is powered by four wires 103, one of which is a ground conductor. Canopy device 100 also includes a power cable 104, and power cable 104 includes four wires 105, one of which is a ground conductor. In order to couple the wires 105 of the supply cable 104 to the wires 103 of the motor 102, an electrical coupling 200 is provided that includes a male component 210 and a female component 220, which male component 210 and female component 220 may be electrically and mechanically coupled together. In this embodiment, the female connector 220 has been connected to the mounting 110, the mounting 110 having been attached to the housing of the canopy device before the canvas package comprising the roll-up canopy 101 and the electric motor 102 is inserted in the direction indicated by numeral 111.

The male component 210 in fig. 2 includes a printed circuit board 213 (PCB) on which an electrical connector as a lip 212 is electrically coupled to printed conductors 214 on the printed circuit board 213. These printed conductors are electrically coupled one to the electric wires 103 of the motor 102 in this case. This is accomplished using a griplet connector 216. The male member 210 in this embodiment includes two

lips

212 and 218. The lip 218 is specifically coupled to ground and is slightly longer than the other lip 212. One of the printed conductors 219 on this lip 218 is also longer and therefore protrudes further from the printed circuit board than the other conductors on the other lip 212. This printed conductor 219 is coupled to ground. This conductor 219 on the lip 218 is also wider and slightly thicker.

The female component 220 in fig. 3 includes a printed circuit board 223 (PCB), on which printed circuit board 223 (PCB) an electrical connector, here a spring contact 222, as an electrically conductive contact object is electrically coupled to a printed conductor 224 on the printed circuit board 223. The printed conductors are electrically coupled to the wires of the power supply cable 104. This is achieved using a griplet connector 226. Female component 220 includes five spring contacts 222. In the center, the female member has a grounding fin 227 for grounding the housing. Two spring contacts 228 are coupled to ground. Two spring contacts are provided for contact with the printed ground conductor 219 of the male member on the lip 218. The other contact 214 of the male component is contacted by a spring contact 222.

The printed

circuit boards

213 and 223 have a length of about 35 mm to 58 mm, a width of about 12 mm to 15mm, and a thickness of 1.6mm, and are made of glass fabric reinforced epoxy resin.

Conductors

214 and 224 preferably have a surface area weight of 1 to 2 ounces per square foot and are made of copper. The conductor coupled to the ground wire preferably has a surface area weight of 2 ounces per square foot. The cross-sectional area of the conductor is preferably 0.106mm for a surface area weight of 2 ounces per square foot ² Or greater. The lip protrudes 6.7mm from the edge of the printed circuit board. The printed contact end was 2.5 mm from the lip end, except for the conductor coupled to ground (with its end 1mm from the lip end). Thus, upon coupling, the conductor coupled to the grounded lip 218 will first contact two spring contacts 222, and then the other printed conductors of the male component will contact the spring contacts 222. The ends of the printed conductors on the lip of the male member may be coated with a conductive coating that prevents corrosion, such as a gold coating.

The spring contacts are made of metal, preferably Cu or Cu alloy (e.g., cuBe alloy, e.g., 1.7-19%. The spring contacts may or may not be zinc plated or hard gold coated to prevent corrosion.

An alternative male part 211 and female part 221 are shown in figure 4 together with their housings. Here, the male part 211 has four

lips

212 and 218, one conductive printed

conductor

214 or 219 being located on each lip. The ground wire is electrically coupled to a printed conductor 219 on the lip 218. Female part 221 is provided with the same contact object as female part 220 and has two openings 254, each opening 254 receiving two lips.

The printed circuit board is completely enclosed by the

respective housings

230 and 250 except for the

lips

212 and 218 of the male member 210. In female part 220, an opening 254 is made in the housing to allow lip 212 to make contact with an electrically conductive contact object.

In this embodiment, the male part 211 has two projecting fins 231 which project beyond the lip 212, one fin on each side of the male part. However, the fin 231 on the lower side in the drawing is divided into two

parts

231a and 231b.

On these fins 231, the male part 211 has two protrusions 232 in the housing 230 of the male part 211, which protrusions 232 slide into two recesses or recesses 252 during coupling with the female part 221. The fins 231 effectively partially comprise the housing 250 of the female part 221. The fins, and of course the male part, guide and manipulate the male and female parts during coupling. During coupling, the protrusion 232 and the depression 252 first touch each other and guide the movement of the members before the lip 212 is introduced into the opening 254, and thus before the ground conductors contact each other, after which the other conductors contact.

Further, the shell 250 of the female part 220 has a reinforcing region 253, and the reinforcing region 253 increases the rigidity of the entire shell 250. In the opening 254 of the female part 221, a notch 255 is provided for receiving a corresponding sealing ring which, after coupling with the male part, receives one of the lips and seals the coupling of the lips watertight in the opening.

Details of the coupling between the male component 210 and the female component 220 are shown in fig. 5. In detail, a conductor 219 is shown electrically coupled to ground and a spring contact 222a is shown coupled to ground. When the male component 210 and the female component 220 are coupled in the coupling direction 500, the ground conductor coupled to the male component will contact the corresponding spring contact 222a earlier than the other conductors 214 coupled to the other spring contacts 222 b.

Fig. 6 shows in detail how the

female part

220 or 221 is manufactured to the housing of the

male part

210 or 211. A housing 260 or 270 is provided comprised of a

lower member

261 or 271 and a top member or closure member 262 or 272, respectively.

The shell part is made of PA or PVC with a minimum wall thickness of 0.5mm and 2 mm. They are produced by injection moulding.

A printed circuit board provided with a contact object or contact lip is located in the carrier 261.

After introduction of the printed circuit board, the top part is placed on the bottom part and the two housing parts are attached to each other via a

closing system

263a and 263b or 273a and 273b, respectively. In addition, the opening 254 remains free in the female component. In the male member,

lips

218 and 212 project from the housing, i.e. from the shell.

An alternative way of forming the male part with the shape shown in figure 6 is to clamp the printed circuit board 213 in a mould, with the mold holding, for example,

lips

218 and 212 from the mold interior. The mold has a shape similar to the contour of the housing of closure members 271 and 272, and is completely filled with a polymer, preferably PA or PVC. In this way, a male part is formed having a profile as shown in fig. 6, but wherein the housing is formed by injection moulding and wherein the printed circuit board is completely encased by the polymer except for the lip.

An alternative way of forming the female part with the shape shown in fig. 6 is to place the printed circuit board 213 on the lower part 261 and clamp the combination in a mould. The mold has a shape similar to the shell profile of the top piece 262, and is completely filled with a polymer, preferably PA or PVC. In this way a female part is formed having the profile as shown in fig. 6, but wherein the housing is formed partly by injection moulding and partly by the casing, and wherein the printed circuit board is completely encased in the polymer except for the opening.

Fig. 7 shows an alternative component suitable for installation in a canopy device, which may be installed on both the left and right sides. Female component 2200 is coupled to current carrying cable 104. Behind

openings

2201a and 2201b are contact objects, such as springs or clamping contacts, coupled to the ground conductors of the cable. Behind

openings

2202a and 2202b is a contact object electrically coupled to a first of the two current carrying wires. Behind

openings

2203a and 2202b is a contact object electrically coupled to a second of the two current carrying wires. The female component 2200 may be coupled to the same motor on the left and right sides.

Another canopy device 1100 according to the present invention is shown in fig. 8, which includes a roll-up canopy 1101 and an electric motor 1102 for rotating the roll-up canopy. The motor 1102 is powered by four wires 1103, one of which is a ground conductor. In addition, canopy device 1100 includes a power cable 1104, and power cable 104 includes four wires 1105, one of which is a ground conductor. To couple the wires 1105 of the supply cable 1104 to the wires 1103 of the motor 1102, an electrical coupling 1200 is provided that includes a male component 1210 and a female component 1220, which may be electrically and mechanically coupled together by the male component 210 and the female component 220. In this embodiment, the male connector 1210 has been attached to the mount 1110, and the mount 110 has been secured into the housing of the canopy device before the canvas bag including the roll-up canopy 1101 and electric motor 1102 is inserted in the direction indicated by numeral 1111.

A top and bottom view of a portion of the male member 1210 is shown in fig. 9. The male component includes a printed circuit board 1213 (PCB), electrical connectors on the printed circuit board 1213 (PCB), i.e., contact pins 1212 a-1212 d, are electrically coupled to the printed conductors 1214 on the printed circuit board 1213. These printed conductors are electrically coupled to the wires of the power supply cable 104. This is accomplished using a nickel coated copper griplet connector 1216. The male element 1210 in this embodiment includes four contact pins 1212 a-1212 d. Contact pin 1212a is coupled to a wire carrying a conducting neutral, and

contact pins

1212b and 1212c are each coupled to a wire carrying an alternating phase. Contact pin 1212d is a contact pin 1218 that is coupled to ground and is slightly longer than the other contact pins. In the center, the male member has grounding fins 1227 for grounding the housing.

The female part 1220 in fig. 10 comprises a printed circuit board 1223 (PCB), on which printed circuit board 1223 (PCB) the electrical connectors as contact sockets 1222a to 1222d are electrically coupled to printed conductors 1224 on the printed circuit board 1223. The printed conductors are electrically coupled to the wires 1103 of the motor 1102. This is accomplished using a griplet connector 1226 that is the same as the griplet connector 1216. The female part 1220 includes four contact sockets 1222a to 1222d. The contact receptacle 1222d is a contact receptacle 1228 coupled to ground and slightly longer than the other contact receptacles. The contact receptacle 1222a is coupled to a conducting neutral wire, and the

contact receptacles

1222b and 1222c are each coupled to a wire carrying an alternating phase.

The printed

circuit boards

1213 and 1223 have a length of about 35 mm to 58 mm, a width of about 12 mm to 15mm, and a thickness of about 1.6mm, and are made of glass fiber tissue reinforced epoxy resin. The

conductors

1214 and 1224 preferably have a surface area weight of 1 to 2 ounces per square foot, and is made of copper, and in some cases has a hard gold coating. The conductor coupled to the ground wire preferably has a gauge of 2 ounces per square footArea weight. The cross-sectional area of the conductor is preferably 0.106mm for a surface area weight of 2 ounces per square foot ² Or greater.

The contact pins are made of copper, preferably with a hard gold coating, and have a length of about 0.22 inches, except for the contact pins that are coupled to the ground conductors, which have a length of 0.28 inches. The contact pins were 0.05 inches in diameter. The contact receptacle is made of copper, preferably with a hard gold coating, and has a length of 0.25 inches and an opening diameter adapted to receive a 0.05 inch pin.

Since the contact pin connected to ground and the contact socket connected to ground are long, the contact pin and the socket come into contact before the three other contact pins and sockets come into contact when the components 1210 to 1220 are coupled.

The male component 1210 and the female component 1220 are shown in fig. 11 along with their housings.

The printed circuit board is completely enclosed by the

respective housing

1230 or 1250.

In the housing 1230, the four contact pins are axially surrounded by an electrically isolating wall 1233, wherein no contact is made between the contact pin 1212 and this wall 1223. The contact pins 1212 do not protrude outside the wall 1233 in the axial direction, and the open region 1234 is held between the wall 1233 and the contact pins 1212. In addition to protecting the contact pins, this wall 1233 also has a second function, namely a secondary guidance of the coupling movement.

The contact sockets 1222 of the female part 1220 are axially surrounded by an electrically isolating socket wall 1255, wherein the contact is made in axial direction along the entire socket wall 1255. As shown in this embodiment, the top receptacle wall 1255 is level with the contact receptacle 1222 or projects slightly above the contact receptacle 1222. The socket wall 1255 fits between the contact pin 1212 and the wall 1233 surrounding the contact pin. It fits into and thus slides into the open area 1234. During the coupling of the male and female parts, the socket wall 1255 has a guiding function. The receptacle wall is slightly conical, and if receptacle wall 1255 and open area 1234 are not precisely opposite each other during coupling, the conical wall of receptacle wall 1255 will manipulate incoming receptacle 1222 into the correct position.

At the bottom of each contact receptacle 1222, around the receptacle wall 1255 surrounding the contact receptacle, a sealing ring 256 is provided for watertight sealing of the coupled contact pin and socket. This ring 1256 also fits into a small recess 1235 provided in the wall 1233 at the top.

In another embodiment (not shown), the female part has two guide pins which slide into two openings of the housing of the male part during coupling with the male part. Wherein the prongs and openings are in particular handling elements which handle the movement of the male part and the female part during coupling of the male part and the female part in the coupling direction.

The shell of the female component may also include a reinforced area that increases the stiffness of the overall shell.

Details of the coupling between the male component 1210 and the female component 1220 are shown in fig. 12a and 12 b. Specifically, contact pin 1218 is shown electrically coupled to ground, as well as contact pin 1212 (i.e.,

contact pin

1212a, 1212b, or 1212 c) electrically coupled to a current conducting or current carrying wire or neutral. During coupling of the male part 1210 with the female part 1220 in the coupling direction 1500, the contact pins 1218 will first come into contact with the corresponding contact sockets 1222. This is shown in fig. 12 a. As shown in fig. 12b, only then are the other contact pins 1212 in contact with their corresponding contact sockets 1222.

Fig. 13 shows in detail how the housing of the female part 1220 is produced. A shell 1260 is provided consisting of a carrier 1261 and a cover or closure 1262.

The housing is made of PA or PVC with a minimum wall thickness of 0.5mm to 2 mm.

A printed circuit board coupled to the power supply cable and provided with contact sockets is located in the carrier 1261. The open volume above and below the printed circuit board in the carrier 1261 is filled with a volume of polymer, preferably PA or PVC. This polymer melts during the casting process. After filling with polymer, closure member 1262 is installed, with the contact sockets being guided into upstanding portions 1263, and the polymer volume can cool and harden.

Male component 1210 is similarly produced, with carrier 1271 shown in fig. 13.

Fig. 14 shows an alternative component which is adapted to be mounted in a canopy device which can be mounted on both the left and right side.

In this embodiment, the female component 3220 is also coupled to the wires of the power supply cable 1104 by a griplet connector 3226, and this female component has a grounding fin 3227. Six contact receptacles 3222 are coupled to the PCB 3223. The contact receptacle 3222d is coupled to a ground wire. The two contact sockets 3222a are coupled to a neutral wire of the power supply cable. When connected to a male component comprising only four pins on the left and right sides, in both cases the ground pin and the neutral pin are connected to the ground 3222d and the neutral receptacle 3222a by contact with one of the two

receptacles

3222a or 3222 d. The two remaining

contact receptacles

3222b and 3222c are each electrically coupled to one of the current carrying wires of the power supply cable. In both left and right mounting options, a current-carrying contact socket is in contact with a contact pin, so that current can be transmitted.

Although the present invention has been described by way of specific embodiments, it will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that various changes and modifications may be made without departing from the scope of the invention as defined in the appended claims. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is assumed that this covers all changes, variations or equivalents that fall within the scope of the application of the basic underlying principles and the essential attributes claimed in this patent application. Furthermore, readers of the present patent application will understand that the term "comprising" or "comprises" does not exclude other elements or steps, that the term "a (n))" does not exclude a plurality, and that a single element, such as a computer system, a processor or another integrated unit may fulfill the functions of various means of assistance as recited in the claims. Any reference in the claims should not be construed as limiting the respective claim. The terms "first," "second," "third," "a," "b," "c," and the like as used in the description or in the claims, are used for distinguishing between similar elements or steps and not necessarily for indicating a sequential or chronological order. Also, the terms "top side," "bottom side," "above," "below," and the like are used for descriptive purposes, and not necessarily relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention are capable of operation in other sequences or orientations than described or illustrated herein.

Claims

1. A method of manufacturing a canopy device, the canopy device comprising a roll-up canopy; an electric motor to rotate the roll-up canopy, the motor being powered by a power supply cable comprising one or more wires; an electrical connector for coupling the wires of the supply cable to the wires of the motor, the electrical connector comprising a male part and a female part, the male part and female part being electrically and mechanically coupleable together, the male part comprising a Printed Circuit Board (PCB) having at least one printed conductor electrically coupled to at least one wire of a first one of the motor and supply cable, wherein the female part comprises a Printed Circuit Board (PCB) having at least one printed conductor electrically coupled to at least one wire of the other one of the motor and supply cable, wherein the method comprises steps a and/or B; the step A is as follows:

a1. Providing a Printed Circuit Board (PCB) comprising at least one lip having thereon at least one printed conductor electrically coupled to at least one conductor of a first one of the motor and the supply cable, or comprising at least one contact pin electrically coupled to at least one printed conductor on the printed circuit board, the at least one printed conductor being electrically coupled to at least one electric wire of a first one of the motor and the supply cable;

introducing the printed circuit board into a first housing and/or a first mould, wherein the at least one lip or the at least one contact pin is located outside the first housing and/or the first mould;

filling said first housing and/or first mould containing said printed circuit board with a polymer;

the step B is as follows:

providing a Printed Circuit Board (PCB), at least one electrically conductive contact object or at least one contact socket on said Printed Circuit Board (PCB) being electrically coupled to at least one printed conductor on said printed circuit board, said at least one printed conductor being electrically coupled to at least one wire of said other one of said motor and said supply cable;

b2, introducing the printed circuit board into a first housing and/or a first mould;

b3 filling the first housing and/or the first mould containing the printed circuit board with a polymer, wherein the at least one electrically conductive contact object or contact receptacle remains accessible from outside the first housing.

2. The method of claim 1, wherein step a is performed.

3. The method of claim 2, wherein step A2 comprises introducing the printed circuit board into a first mold, wherein the at least one lip or the at least one contact pin is located outside the first mold.

4. Method according to one of the preceding claims, wherein step A2 comprises introducing the printed circuit board into a first housing, wherein the at least one lip or the at least one contact pin is located outside the first housing.

5. The method according to one of claims 1 or 2, wherein step A2 comprises providing a housing in the first mould before the printed circuit board from step A1 is introduced into the first mould.

6. A method according to claim 4 or 5, wherein the method comprises a step A4, in which step A4 the housing is closed by a closure.

7. The method of any one of claims 2 to 6, wherein step A1 comprises providing a Printed Circuit Board (PCB) comprising at least one lip having at least one printed conductor thereon electrically coupled to at least one wire of a first one of the motor and the supply cable.

8. The method of any one of claims 2 to 6, wherein step A1 comprises providing a Printed Circuit Board (PCB) comprising at least one contact pin electrically coupled to at least one printed conductor on the PCB, the at least one printed conductor being electrically coupled to at least one wire of a first one of the motor and the supply cable.

9. The method of claim 1, wherein step B is performed.

10. The method of claim 9, wherein step B2 comprises introducing the printed circuit board into a first mold, wherein the at least one lip or the at least one contact pin is located outside the first mold.

11. The method of claim 9, wherein step B2 comprises introducing the printed circuit board into a first housing, wherein the at least one lip or the at least one contact pin is located outside the first housing.

12. The method of claim 9, wherein step B2 comprises providing a housing in a first mold prior to introducing the printed circuit board from step A1 into the first mold.

13. A method according to claim 11 or 12, wherein the method comprises step B4, in which step B4 the outer shell is closed by a closure.

14. The method of any one of claims 9 to 13, wherein step B1 comprises providing a Printed Circuit Board (PCB) comprising at least one electrically conductive contact object electrically coupled to at least one printed conductor on the PCB, the at least one printed conductor being electrically coupled to at least one wire of the other of the motor and the supply cable.

15. The method of any one of claims 9 to 13, wherein step B1 comprises providing a Printed Circuit Board (PCB) comprising at least one contact receptacle electrically coupled to at least one printed conductor on the PCB, the at least one printed conductor being electrically coupled to at least one electrical wire of the other one of the motor and the supply cable.

16. The method according to any of the preceding claims, wherein steps a and B are performed.

17. The method according to any of the preceding claims, wherein the filling is performed with a thermoplastic polymer or an elastomeric polymer.