CN117199889A

CN117199889A - Overmolded printed circuit board and connector with integrated upstanding mounting and ground connection

Info

Publication number: CN117199889A
Application number: CN202310665342.4A
Authority: CN
Inventors: D·波特罗德里格斯; J·D·贝尔; E·赫里巴
Original assignee: Vitesco Technologies USA LLC
Current assignee: Vitesco Technologies USA LLC
Priority date: 2022-06-06
Filing date: 2023-06-06
Publication date: 2023-12-08

Abstract

The application relates to an overmolded printed circuit board and connector with integrated upstanding mounting and ground connection. A control unit that meets desired packaging requirements, eliminates the need for right angle or L-shaped pins, and has a reduced footprint. The control unit includes a connector, a circuit board connected to the connector, and a package housing. The package housing surrounds at least a portion of the circuit board and at least a portion of the connector. The connector includes a base flange, a shroud integrally formed with the base flange, a plurality of pins extending through the base flange and partially into the circuit board. The connector also includes at least one ground pin connected to a base flange that extends partially into the circuit board. The bushing extends through a mounting post formed as part of the base flange such that the bushing contacts the ground pin, wherein the ground pin and bushing are part of a ground connection.

Description

Overmolded printed circuit board and connector with integrated upstanding mounting and ground connection

Cross Reference to Related Applications

The application claims the benefit of provisional application 63/349, 579 filed 6/2022. The disclosures of the above applications are incorporated herein by reference.

Technical Field

The present application relates generally to a control unit having an upstanding connection structure that includes a connector, a vehicle mounting location integrated into the connector, and the connector and PCB are over-molded together, wherein the PCB may be filled or unfilled, or the PCB may be part of an electronic subassembly that also includes other electronic components.

Background

Control units are commonly used to control various components of a vehicle's drive train, such as an engine, transmission, or transfer case. The design and configuration of the control unit becomes more stringent due to thermal management and various packaging requirements. Various existing designs of control units include pre-molded connector pins that have a right angle or L-shape and are longer than desired, have an undesirable footprint, and require additional over-molding material to cover the L-shaped connector pins. Some control units also require additional brackets to mount to the vehicle and achieve the desired orientation of the printed circuit board.

Accordingly, there is a need for a control unit that overcomes the above-described drawbacks, meets the desired packaging requirements, and has a simpler construction.

Disclosure of Invention

In one embodiment, the present application is a control unit that meets the desired packaging requirements, eliminates the need for right angle or L-shaped pins, and has a reduced footprint.

In one embodiment, the application is a control unit that includes a connector, a circuit board connected to the connector, and a package housing. The package housing surrounds at least a portion of the circuit board and at least a portion of the connector.

In one embodiment, a connector includes: a base flange; a shroud integrally formed with the base flange; a plurality of pins extending through the base flange such that a portion of each of the plurality of pins is surrounded by the shroud and another portion of each of the plurality of pins extends into the circuit board. The connector also includes at least one ground pin connected to the base flange. A portion of the at least one ground pin extends through the base flange and into the circuit board.

In one embodiment, at least one mounting post is integrally formed as part of the base flange, and at least one bushing extends through the mounting post and contacts the ground pin. The bushing extends through the mounting post such that the bushing contacts the ground pin. In one embodiment, the ground pin and bushing are part of a ground connection.

In one embodiment, the ground pin includes a ring portion adjacent to and in contact with the mounting post such that the ring portion is in contact with the bushing.

In one embodiment, the ground pin includes a flange portion integrally formed with the ring portion, and the flange portion is in contact with and supported by the mounting post.

In one embodiment, the ground pin includes a pin portion, and the pin portion extends through the base flange and into the circuit board.

In one embodiment, the ground pin includes a body portion, at least one barb integrally formed as part of the body portion, and at least one side flange integrally formed as part of the body portion. The body portion is inserted through the base flange such that the side flange contacts the base flange and the barb prevents the ground pin from being disconnected from the connector.

In one embodiment, the connector includes a plurality of support ribs, and each of the support ribs contacts the circuit board and supports the connector when the connector is connected to the circuit board.

In one embodiment, the connector includes a plurality of crush ribs and a plurality of support ribs. When the connector is connected to the circuit board as the support rib is in contact with the circuit board, each of the pressing ribs is deformed. Optionally including crush ribs so that the connector can be assembled without the use of crush ribs.

In one embodiment, the connector includes a peripheral support wall, and at least one of the crush ribs is integrally formed as part of the peripheral support wall.

In one embodiment, the package housing is formed during an injection molding process.

In one embodiment, the circuit board is a printed circuit board, and in yet another embodiment, the circuit board is a filled printed circuit board. The circuit board may also be part of an electronic subassembly that also includes other electronic components.

Further areas of applicability of the present application will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the application, are intended for purposes of illustration only and are not intended to limit the scope of the application.

Drawings

The present application will become more fully understood from the detailed description and the accompanying drawings, wherein:

fig. 1 is a front view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 2 is a side view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 3 is an exploded view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 4A is an exploded view of a connector used as part of a control unit having an upright connection structure and a ground connection in accordance with an embodiment of the present application;

FIG. 4B is a front view of a connector used as part of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 4C is a perspective view of a ground pin used as part of an upright connection structure and ground connection in accordance with an embodiment of the present application;

FIG. 4D is a perspective view of several components of a control unit with an upright connection and a ground connection according to an embodiment of the present application;

FIG. 4E is a perspective view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 5A is a partially exploded view of a pre-assembly that is part of a control unit having an upright connection structure and a ground connection, according to an embodiment of the present application;

FIG. 5B is a bottom view of a preassembly according to an embodiment of the present application, which is part of a control unit having an upright connection structure and a ground connection;

FIG. 6 is a perspective view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

fig. 7 is a partially exploded perspective view of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 8A is a rear view of a connector used as part of a control unit having an upright connection structure and a ground connection according to an embodiment of the present application;

FIG. 8B is a cross-sectional view taken along line 8B-8B in FIG. 4B;

FIG. 8C is an enlarged view of the portion labeled 8C in FIG. 8B;

FIG. 8D is a perspective view of a portion of a connector that is part of a control unit having an upright connection structure and a ground connection, according to an embodiment of the present application; and

fig. 8E is an enlarged view of the portion labeled 8E in fig. 8D.

Detailed Description

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the application, its application, or uses.

An embodiment of a control unit having an upright connection structure and a ground connection is shown generally at 10 in fig. 1-3. The control unit 10 includes a connector, shown generally at 12, a Printed Circuit Board (PCB) 14, and a package housing 16.

The connector 12 includes a shroud 18 integrally formed with a base flange 20. The connector 12 also includes a plurality of pins, shown generally at 22, each of which extends through the base flange 20 of the connector 12 such that a portion of each of the plurality of pins 22 is located in a cavity, shown generally at 24, surrounded by the shroud 18. A first mounting post 26a having a first aperture 28a and a second mounting post 26b having a second aperture 28b are also integrally formed with the base flange 20. On opposite sides of the base flange 20 relative to the mounting posts 26a, 26b are a first support post 64a and a second support post 64b.

Referring to fig. 4A-4E, the connector 12 further includes two ground pins, shown generally at 30a, 30b, respectively. Each ground pin 30a, 30b has a pin portion 32a, 32b, a body portion 34a, 34b, and a ring portion 36a, 36b with a corresponding aperture 38a, 38 b. Referring specifically to fig. 4C, there is shown a first ground pin 30a, with the body portion 34A and the ring portion 36a being connected by a flange portion 62 (the second ground pin 30b also has a flange portion shown but not labeled in fig. 4A). The thickness of flange portion 62 enables ring portion 36a to deflect relative to body portion 34a to accommodate various tolerances during assembly. Integrally formed with the body portion 34A are a plurality of barbs 60 and two side flanges 66a, 66b (the body portion 34b of the second ground pin 30b also includes barbs and side flanges, as shown in fig. 4A and 4D-4E).

When assembled, the pin portion 32a and the body portion 34a of the first ground pin 30a extend through the base flange 20 and into the first support post 64a such that the side flanges 66a, 66b are in contact with the base flange 20, the flange portion 62 and the side flanges 66a, 66b of the first ground pin 30a are in contact with and supported by the first mounting post 26a, and the aperture 3sa of the first ground pin 30a is aligned with the aperture 28a of the first mounting post 26 a. In addition, when assembled, the leg portion 32b and the body portion 34b of the second ground leg 30b extend through the base flange 20 and into the second support post 64b such that the side flange is in contact with the base flange 20, the flange portion and the side flange of the second ground leg 30b are in contact with the second mounting post 26b and supported by the second mounting post 26b, and the aperture 38b of the second ground leg 30b is aligned with the aperture 28b of the second mounting post 26 b. The ground pins 30a, 30b are intended to be permanently connected to the base flange 20 and the corresponding support posts 64a, 64b such that the barbs 60 prevent the ground pins 30a, 30b from being removed without causing catastrophic failure of the connector 12. The side flanges 66a, 66b limit the distance the ground pins 30a, 30b can be inserted through the base flange 20 and support posts 64a, 64b. The barbs 60 and side flanges 66a, 66b provide for proper positioning of the ground pins 30a, 30b to ensure that the apertures 38a of the first ground pin 30a are aligned with the first apertures 28a of the first mounting post 26a and the apertures 38b of the second ground pin 30b are aligned with the apertures 28b of the second mounting post 26b when assembled.

The support posts 64a, 64b have openings through which the pin portions 32a, 32b extend such that at least a portion of each of the pin portions 32a, 32b protrudes beyond the support posts 64a, 64b. The portion of each of the pin portions 32a, 32b that protrudes beyond the support posts 64a, 64b extends through the PCB 14.

Referring to fig. 4A-5B, when the connector 12 is connected to the PCB 14, a portion of each of the plurality of pins 22 extends through the PCB 14 and a portion of each of the pin portions 32a, 32B also extends through the PCB 14. The pins 22 and ground pins 30a, 30b are straight and have no bends. The pins 22 and ground pins 30a, 30b may be assembled to the connector 12 by insertion into the connector 12, or the connector 12 may be molded around portions of the pins 22 and ground pins 30a, 30b by an injection molding process. It is within the scope of the present application that pins 22 and ground pins 30a, 30b may be assembled to connector 12 using a stitch process, an overmolding process, a combination of pre-and overmolding processes, and the like.

Integrally formed with the base flange 20 are a first alignment post 40a and a second alignment post 40b. The first alignment post 40a extends through a first alignment aperture 42a integrally formed as part of the PCB 14 and the second alignment post 40b extends through a second alignment aperture 42b integrally formed as part of the PCB 14.

The control unit 10 further comprises two bushings 44a, 44b, wherein the bushings 44a, 44b and the ground pins 30a, 30b provide a ground connection for the PCB 14. The first bushing 44a is partially disposed in the first aperture 28a and is in contact with the ring portion 36a of the first ground pin 30a such that the aperture 46a of the first bushing 44a is aligned with the aperture 38a of the first ground pin 30 a. The second bushing 44b is partially disposed in the second aperture 28b and is in contact with the ring portion 36b of the second ground pin 30b such that the aperture 46b of the second bushing 44b is aligned with the aperture 38b of the second ground pin 30 b. The apertures 46a, 46b of the bushings 44a, 44b are approximately the same diameter as the apertures 38a, 38b of the ground pins 30a, 30 b.

The package housing 16 substantially surrounds substantially all of the PCB 14 except for the area where the PCB 14 contacts portions of the connector 12. As shown in fig. 1, the package housing 16 also surrounds a portion of the base flange 20. More specifically, referring to fig. 1 and 5A-7, the package housing 16 surrounds the peripheral side wall 48 of the base flange 20 and also surrounds a portion of the outer surface 50 of the base flange 20. The package housing 16 includes a lip portion 52, and the lip portion 52 is the portion of the package housing 16 that covers a portion of the outer surface 50 of the base flange 20. The lip portion 52 has a width 52a shown in fig. 1, the width 52a being constant over the entire length of the lip portion 52.

Referring to fig. 5B and 8A-8E, the base flange 20 further includes a rear surface 54, and the support posts 64a, 64B are integrally formed with the base flange 20 such that the support posts 64a, 64B extend away from the rear surface 54. The connector 12 also includes a plurality of crush ribs 56 and a plurality of support ribs 58. Also integrally formed with the rear surface 54 and extending away from the rear surface 54 is a peripheral support wall 68, and integrally formed with the peripheral support wall 68 is one of the crush ribs 56. More specifically, as shown in fig. 8A and 8D-8E, the crush rib 56a is integrally formed as part of a peripheral support wall 68, wherein the peripheral support wall 68 encloses the plurality of pins 22 protruding through the base flange 20. As shown in fig. 8A and 8D-8E, some of the support ribs 58 are integrally formed with the peripheral support wall 68 and extend away from the rear surface 54. Another crush rib 56b is integrally formed as part of the first support column 64a, and yet another crush rib 56c is integrally formed as part of the second support column 64b. The second crush rib 56b surrounds the pin portion 32a of the first ground pin 30a, and the third crush rib 56c surrounds the pin portion 32b of the second ground pin 30 b.

It should be noted that in alternative embodiments, a back potting connector (back potted connector) may be used in place of the illustrated connector 12, and is within the scope of the application.

Referring generally to the drawings, during assembly, as previously described, the pins 22 and ground pins 30a, 30b are assembled to the base flange 20. The connector 12 is then positioned for assembly to the PCB 14. To assemble the connector 12 to the PCB 14, the first alignment post 40a is aligned with the first alignment aperture 42a and the second alignment post 40b is aligned with the second alignment aperture 42b. During assembly, the outer surface 50 of the base flange 20 serves as a tool pressing area, wherein forces are applied to the outer surface 50 of the base flange 20 in areas of the base flange 20 not occupied by the shroud 18 or mounting posts 26a, 26 b. In alternative embodiments, force may be applied to both the base flange 20 and the shroud 18. The crush ribs 56 protrude further outward than the support ribs 58 and a force is applied to the base flange 20 and/or the shroud 18 such that the crush ribs 56 deform and the support ribs 58 then contact the PCB 14 under a predetermined force load and, in addition, the first alignment posts 40a extend into the first alignment apertures 42a and the second alignment posts 40b extend into the second alignment apertures 42b. Once the connector 12 is in the desired position relative to the PCB 14, the force applied to the base flange 20 and/or the shroud 18 is distributed between the support ribs 58, the support posts 64a, 64b, and the peripheral support wall 68. When one or more of the pins 22 are connected to the PCB 14 using solder or other type of connection, the force applied to the base flange 20 is maintained.

In an alternative embodiment, the crush ribs 56 are not used, and instead the support ribs 58, support columns 64a, 64b, and peripheral support walls 68 are used to support the connector 12 when force is applied to the base flange 20 during this step of the assembly process.

The connection of the connector 12 and the PCB 14 forms a "pre-assembly" and once the soldering process is completed, the pre-assembly is placed into a tooling device or molding device, where several holding devices, such as clamps or the like, hold the pre-assembly in place while resin or some type of plastic material is injected into the tooling device during the over-molding process. The resin/plastic material is injected into the tooling device to form the package housing 16, which package housing 16 surrounds the various portions of the PCB 14 and the base flange 20 of the connector 12 as previously described. The over-molding process also results in a portion of the package housing 16 being disposed between the PCB 14 and the base flange 20. There is a portion of the enclosure 16 that surrounds the support posts 64a, 64b, the peripheral support walls 68, and the support ribs 58 that are not surrounded by the peripheral support walls 68. Referring to fig. 3, there is an exploded view of the control unit 10, which depicts the connector 12, PCB 14 and package housing 16 separately, however, the connector 12, PCB 14 and package housing 16 are connected together during the over-molding process and cannot be separated without catastrophic damage to the control unit 10.

After the overmolding process is complete, the bushings 44a, 44b are inserted into the apertures 28a, 28b such that the bushings 44a, 44b are positioned in the apertures 28a, 28b as described above. When the bushings 44a, 44b are inserted into the apertures 28a, 28b, the ring portion 36a, 36b of each ground pin 30a, 30b is supported to prevent any portion of the ground pins 30a, 30b from deflecting during this step of the assembly process.

Once the bushings 44a, 44b are assembled to the mounting posts 26a, 26b, fasteners may be inserted through the apertures 38a, 38b of the ground pins 30a, 30b and through the apertures 46a, 46b of the bushings 44a, 44b, respectively, to mount the control unit 10 in a desired manner. The combination of the ground pins 30a, 30b, bushings 44a, 44b and fasteners provides two ground connections. Fasteners pass through the bushings 44a, 44b and the desired ground connection may be achieved by placing the bushings 44a, 44b in physical contact with the chassis of the vehicle by the fasteners, or the fasteners may be in contact with the respective ground pins 30a, 30b and the metal component to which the fasteners are connected. As mentioned above, the flange portion 62 of the first ground pin 30a is able to flex and deflect such that when one of the fasteners is inserted through the aperture 38a of the ring portion 36a and the bushing 44a, if the ring portion 36a is not already in contact with the bushing 44a, the ring portion 36a is placed in contact with the bushing 44a when the fastener is tightened (the flange portion of the second ground pin 30b functions in a similar manner).

In addition, the orientation of the PCB 14 relative to the connector 12 and the retention together by the package housing 16 provide an upstanding connection structure, eliminating the need for the pins 22 or ground pins 30a, 30b to be L-shaped. The fasteners provide the function of attaching the control unit 10 to the vehicle in a desired manner and are also part of a desired ground connection. The orientation of the connector 12, PCB 14 and package housing 16 also helps orient the control unit 10 to meet desired packaging requirements.

The description of the application is merely exemplary in nature and, thus, variations that do not depart from the gist of the application are intended to be within the scope of the application. Such variations are not to be regarded as a departure from the spirit and scope of the application.

Claims

1. An apparatus, comprising:

a control unit, comprising:

a connector;

a circuit board connected to the connector; and

packaging the shell;

wherein the package housing surrounds at least a portion of the circuit board and at least a portion of the connector.

2. The apparatus of claim 1, the connector further comprising:

a base flange;

a shroud integrally formed with the base flange;

a plurality of pins extending through the base flange such that a portion of each of the plurality of pins is surrounded by the shroud and another portion of each of the plurality of pins extends into the circuit board; and

at least one ground pin connected to the base flange;

wherein a portion of the at least one ground pin extends through the base flange and into the circuit board.

3. The apparatus of claim 2, further comprising:

at least one mounting post integrally formed as part of the base flange; and

at least one bushing extending through the at least one mounting post such that the at least one bushing is in contact with the at least one ground pin, the at least one ground pin and the at least one bushing being part of a ground connection.

4. The apparatus of claim 3, the at least one ground pin further comprising:

a ring portion adjacent to and contacting the at least one mounting post;

wherein the ring portion is in contact with the at least one bushing.

5. The apparatus of claim 4, the at least one ground pin further comprising:

a flange portion integrally formed with the ring portion;

wherein the flange portion is in contact with and supported by the at least one mounting post.

6. The apparatus of claim 2, the at least one ground pin further comprising a pin portion, wherein the pin portion extends through the base flange and into the circuit board.

7. The apparatus of claim 2, the at least one ground pin further comprising:

a body portion;

at least one barb integrally formed as part of the body portion; and

at least one side flange integrally formed as part of the body portion;

wherein the body portion is inserted through the base flange such that the at least one side flange contacts the base flange and the at least one barb prevents the at least one ground pin from being disconnected from the connector.

8. The apparatus of claim 1, the connector further comprising:

a plurality of support ribs;

wherein each of the plurality of support ribs contacts the circuit board and supports the connector when the connector is connected to the circuit board.

9. The apparatus of claim 1, the connector further comprising:

a plurality of crush ribs; and

a plurality of support ribs;

wherein each of the plurality of pressing ribs is deformed when the connector is connected to the circuit board and the support rib is in contact with the circuit board.

10. The apparatus of claim 9, the connector further comprising:

a peripheral support wall;

wherein at least one of the plurality of crush ribs is integrally formed as part of the peripheral support wall.

11. The apparatus of claim 1, wherein the encapsulation housing is formed during an injection molding process.

12. The apparatus of claim 1, the circuit board further comprising a printed circuit board.

13. The apparatus of claim 1, the circuit board further comprising a filled printed circuit board.

14. A control unit comprising:

a connector;

at least one mounting post integrally formed as part of the connector;

a circuit board connected to the connector;

at least one ground pin connected to the circuit board and in contact with the at least one mounting post; and

a package housing surrounding at least a portion of the circuit board and at least a portion of the connector;

wherein fasteners are inserted through the at least one ground pin and the at least one mounting post to provide a ground connection and connect the control unit with the vehicle.

15. The control unit of claim 14, the connector further comprising:

a base flange, the at least one ground post being integrally formed with the base flange;

a shroud integrally formed with the base flange;

a plurality of pins extending through the base flange such that a portion of each of the plurality of pins is surrounded by the shroud and another portion of each of the plurality of pins extends through the circuit board; and is also provided with

Wherein the at least one ground pin is connected to the base flange such that a portion of the at least one ground pin extends through the base flange and into the circuit board.

16. The control unit of claim 15, the connector further comprising:

at least one bushing extending through the at least one mounting post such that the at least one bushing is in contact with the at least one ground pin;

wherein the fastener is inserted through the at least one bushing and the at least one ground pin.

17. The control unit of claim 16, the at least one ground pin further comprising:

a body portion;

a flange portion integrally formed with the body portion;

a ring portion integrally formed with the flange portion; and

a pin portion integrally formed with the body portion, the pin portion extending through the base flange and into the circuit board;

wherein the body portion is inserted through the base flange such that the flange portion and the ring portion are in contact with and supported by the at least one mounting post and the ring portion is in contact with the at least one bushing such that the fastener is inserted through the at least one bushing and the ring portion.

18. The control unit of claim 17, the at least one ground pin further comprising:

at least one barb integrally formed as part of the body portion; and

at least one side flange integrally formed as part of the body portion;

19. The control unit of claim 14, the connector further comprising:

a plurality of crush ribs;

a peripheral support wall, at least one of the plurality of crush ribs being integrally formed as part of the peripheral support wall; and

a plurality of support ribs;

wherein each of the plurality of pressing ribs is deformed such that the support rib is in contact with the circuit board when the connector is connected to the circuit board, the plurality of support ribs are in contact with the circuit board, and the plurality of support ribs and the peripheral side support wall support the connector when the connector is connected to the circuit board.

20. The control unit of claim 14, wherein the package housing is formed during an injection molding process.

21. The control unit of claim 14, the circuit board further comprising a filled printed circuit board.

22. A method for manufacturing a control unit, comprising the steps of:

providing a connector;

providing a base flange as part of the connector;

providing at least one mounting post as part of the connector;

providing a shroud as part of the connector;

providing a circuit board;

providing a packaging shell;

providing at least one ground pin;

providing a plurality of pins;

providing at least one bushing;

providing a plurality of crush ribs;

providing a plurality of support ribs;

inserting each of the plurality of pins through the base flange such that each of the plurality of pins is at least partially surrounded by the shroud;

inserting the at least one ground pin at least partially through the base flange such that the at least one ground pin is in contact with the at least one mounting post;

positioning the connector such that one or more of the plurality of crush ribs are in contact with the circuit board;

applying a force to the connector such that the plurality of crush ribs in contact with the circuit board deform and the plurality of support ribs contact the circuit board and a portion of each of the plurality of pins extends through the circuit board and a portion of the at least one ground pin extends through the circuit board;

overmolding an overmold material around a portion of the circuit board and a portion of the connector to form the package housing;

the at least one bushing is partially inserted through the at least one mounting post such that the at least one bushing is in contact with the at least one ground pin.