TW201924149A - A direct plug connector for an ECU - Google Patents

Abstract

The direct plug connector 108 is provided for an Electronic Control Unit (ECU) 102. The ECU 102 comprises a Printed Circuit Board (PCB) 104 withcontact pads 120. The direct plug connector 108 comprises an end cover 112. The end cover 112 comprises a flexible member 118 which functions as a seal. A plurality of contact terminals 110 are arranged through the end cover 112. The plurality of contact terminals 110 makes contact with the contact pads 120 of the ECU 102. A plurality of cables 116 are connected to the plurality of contact terminals 110 with respective stripped ends. The plurality of cables 116 comprises multi-strand wires. The direct plug connector 108 is characterized by, an insulating material sealing a connection between the plurality of contact terminals 110 and the stripped ends of the plurality of cables 116.

Description

Direct plug connector for electronic control unit

The present invention relates to a direct plug connector for a coupling harness to an Electronic Control Unit (ECU), and in particular to prevent malfunction of the ECU due to water ingress.

Due to the rain or pressurized jet flushing fluid, the water passes through the strands of the harness of the carrier and falls on the contact pads of the ECU and the copper traces of the printed circuit board (PCB) of the ECU. Multi-strand cables connect unsealed connectors/joints/other contacts that are responsible for the source/source of water entering various applications of the vehicle (eg, ignition, battery power, starter motors, lights, etc.). Water travels in the interstitial spaces of the multi-strand cable by both gravity and capillary action and falls on the exposed (eg, unmolded or unencapsulated) portion of the PCB. The presence of water acting as an electrolyte on the contact pads of the PCB, as well as the potential difference (voltage) between the power contact pads and adjacent (eg, grounded) contact pads or electrical vias, triggers electrochemical corrosion. Electrochemical corrosion corrodes copper traces that are connected to the remainder of the PCB circuitry, which causes an open circuit. Subsequently, it is not possible to start the carrier due to damage in the power supply to the ECU control circuit. Due to PCB exposure to fluid media, ECUs with Direct Connection System (DCS) or Direct Plug Connector (DPS) are more susceptible to damage, not only in vehicles but also in other electrical and electronic equipment. This is the case.

Therefore, there is a need to prevent media (eg, water) from entering the ECU through multiple strands of wire harness, and subsequent electrochemical corrosion events.

In one aspect, we propose a direct plug connector (108) for an electronic control unit (ECU) (102) that includes a printed circuit board (PCB) having one of the contact pads (120) (104), the direct plug connector (108) includes: a plurality of contact terminals (110) configured to pass through an end cap (112), the plurality of contact terminals (110) and the ECU (102) Contact pad (120) contacts, and a plurality of cables (116) connected to the plurality of contact terminals (110) by respective strip ends, wherein an insulating material is sealed to the plurality of contact terminals (110) a connection to the strip ends of the plurality of cables (116).

102‧‧‧Electronic Control Unit

104‧‧‧Printed circuit board

106‧‧‧Component

108‧‧‧Direct plug connector

110‧‧‧Contact terminals

112‧‧‧End cover

114‧‧‧Pour material

116‧‧‧ cable

118‧‧‧Flexible parts

120‧‧‧Contact pads

202‧‧‧Multiple auxiliary cables

210‧‧‧Bridge terminals

302‧‧‧Single auxiliary cable

304‧‧‧Heat shrinkable pipe fittings

402‧‧‧ Washer

502‧‧‧Anti-wool cable

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the following detailed description of the disclosure, FIG. 1 illustrates a schematic diagram of a direct plug connector having a first connection in accordance with an embodiment of the present invention; FIG. 2 illustrates a second connection in accordance with an embodiment of the present invention. Direct plug connector; FIG. 3 illustrates a direct plug connector having a third connection in accordance with an embodiment of the present invention; FIG. 4 illustrates a direct plug connector having a fourth connection in accordance with an embodiment of the present invention, and FIG. 5 illustrates A direct plug connector having a fifth connection of a specific example of the present invention.

Figure 1 illustrates a direct plug connection with a first connection in accordance with an embodiment of the present invention Schematic diagram of the device. A direct plug connector 108 is provided for use with an electronic control unit (ECU) 102. The direct plug connector 108 can be used in carriers including two-wheeled vehicles, tricycles, four-wheeled vehicles, and other types of vehicles, or in electrical equipment such as washing machines, refrigerators, and the like. The ECU 102 includes a printed circuit board (PCB) 104 having contact pads 120. The direct plug connector 108 includes an end cap 112. End cap 112 is an integral part of direct plug connector 108. End cap 112 houses a flexible member 118, such as a rubber gasket, having a bore for each of a plurality of cables 116. The flexible member 118 also acts as a seal. The end cover 112 is passed through to configure a plurality of contact terminals 110. For the sake of simplicity and clarity of explanation, only one contact terminal 110 is shown in FIG. 1 and is not to be construed as limiting. A plurality of contact terminals 110 contact the contact pads 120 of the ECU 102. A plurality of cables 116 are connected to the plurality of contact terminals 110 by respective strip ends. For the sake of the same simplicity and clear explanation, only one cable 116 is shown, and thus is not to be construed as limiting. The plurality of cables 116 comprise a plurality of wires. The direct plug connector 108 is characterized in that the insulating material seals the connection between the plurality of contact terminals 110 and the strip ends of the plurality of cables 116. Hereinafter, the plurality of contact terminals 110 will be referred to as contact terminals 110, and the plurality of cables 116 will be referred to as cables 116.

Contact terminal 110 is bonded to respective cable 116 by crimping or by other means known in the art. Curling is accomplished on the insulator of cable 116 and the ribbon ends of cable 116. Alternatively, the curling is only done on the strip ends of the cable 116. Each of the contact terminals 110 is connected to a respective cable 116.

ECU 102 includes different components 106, such as random access memory (RAM), input/output (I/O) interface, bus, analog to digital converter (ADC), digital to analog converter (DAC), microprocessor And similar.

The insulating material is selected from the group consisting of infusion material 114, gel and heat shrinkable tubing 304 as shown in FIG. The potting material 114 or gel contains hydrophobic properties and is completely sealed when applied to the connection between the contact terminal 110 and the cable 116. In one specific example, the contact terminal 110 is extended The length extends beyond the flexible member 118 and the connection is sealed outside of the flexible member 118 and inside the end cap 112.

The existing contact terminal 110 is extended beyond the flexible member 118. This extension enables engagement or connection between the contact terminal 110 and the cable 116 containing the plurality of wires. This connection is internal to the available cavity of the end cap 112 of the direct plug connector 108, which is filled with a potting material 114. The potting material 114 prevents water from flowing into the cable 116 into the ECU 102 outside of the sealed connection. The strip end of the cable 116 is in contact with the contact terminal 110 up to a particular length, rather than the entire length.

The portion of the ribbon end of the cable 116 that is reached in the contact terminal 110 is external to the flexible member 118. The remainder toward the contact pad 120 is elongated, i.e., the length is increased. The flexible member 118 also helps prevent the infusion material 114 or gel from flowing onto the PCB 104. The potting material 114 is poured around the extended contact terminal 110 to fill the end cap 112 and seal the vulnerable portion of the contact terminal 110, thereby preventing water from traveling onto the contact pad 120 of the ECU 102.

2 illustrates a direct plug connector having a second connection in accordance with an embodiment of the present invention. The second connection includes a plurality of bridge terminals 210 that connect the strip ends of the cable 116 to the respective contact terminals 110. Additionally, the plurality of bridge terminals 210 are connected to the contact terminals 110 via a plurality of auxiliary cables 202. The plurality of bridge terminals 210 will hereinafter be referred to as bridge terminals 210.

The bridge terminal 210 is an additional terminal that is introduced between the contact terminal 110 and the cable 116. Each of the contact terminals 110 is connected or coupled to the plurality of auxiliary cables 202 to one end of the corresponding bridge terminal 210. The other end of the bridge terminal 210 is attached to the cable 116 of the harness. Insulation material 114 fills the interior of end cap 112 and around bridge terminal 210 to completely prevent water from passing through the joint or second connection. According to the second connection, the water path stops at the bridge terminal 210 without further propagating into the ECU 102.

The bridge terminal 210 is similar or different than the contact terminal 110. Both the bridge terminal 210 and the contact terminal 110 are formed as a single piece of material or a combination of two or more pieces of material that are good electrical conductors.

Figure 3 illustrates a direct plug connection with a third connection in accordance with an embodiment of the present invention Device. The third connection includes a bridge terminal 210 that is connected to the respective contact terminals 110 via a single auxiliary cable 302. The bridge terminal 210 is an additional terminal that is introduced between the contact terminal 110 and the cable 116. The other end of the bridge terminal 210 is attached/connected to the cable 116 of the wire harness including the plurality of wires. The bridge terminal 210 is covered with a respective number of heat shrink tubings 304/sleeves to seal the joint. The heat shrink tubing 304 prevents water from traveling beyond the joint to the ECU 102. The single-strand auxiliary cable 302 is crimped by the insulator at both the contact terminal 110 and the bridge terminal 210. Further, heating the contact terminals 110 and the bridge terminals 210 ensures tight crimping of the cable 116 by the insulator. With the third connection, the water path stops at the bridge terminal 210 without further propagation into the ECU 102. In addition, the single-strand auxiliary cable 302 between the contact terminal 110 and the bridge terminal 210 does not allow water to flow by capillary action.

In other specific examples of the third connection, the infusion material 114 or gel may be used as the insulating material instead of the heat shrinkable tube member 304. In yet another embodiment, both heat shrink tubing 304 and potting material 114 or gel are applied to the joint.

4 illustrates a direct plug connector having a fourth connection in accordance with an embodiment of the present invention. The fourth connection is exactly similar to the third connection, but the gasket 402 is disposed between the bridge terminal 210 and the contact terminal 110. The gasket 402 is disposed around the single-strand auxiliary cable 302. The gasket 402, in conjunction with the single strand of auxiliary cable 302, engages at the bridge terminal 210 to further strengthen the connection, thereby preventing water from traveling into the ECU 102.

Figure 5 illustrates a direct plug connector with a fifth connection in accordance with an embodiment of the present invention. The fifth connection is exactly similar to the third connection, which includes the bridge terminals 210 that are connected to the respective contact terminals 110, but are connected via a plurality of anti-wool cables 502. The other end of the bridge terminal 210 is connected to the cable 116. The capillary resistant cable 502 does not allow water to travel within it. As the case may be, the plurality of bridge terminals 210 are sealed using an insulating material such as a heat shrinkable tube member 304.

For the purposes of clear understanding and illustration, the outer casing sizes of the direct plug connector 108, ECU 102, and other components are shown to be relatively large in all of the connections disclosed in Figures 1 through 5. The actual size during implementation is different and varies according to design requirements.

In accordance with an embodiment of the present invention, various combinations of methods of joining the intermediate joints/connections prior to the flexible member 118 in the end cap 112 of the direct plug connector 108, along with the joining of the upstream and downstream portions of the cable 116 of the harness The water path in the multi-strand cable 116 is broken or becomes discontinuous. Contact terminal 110 is introduced into this connection via or via bridge terminal 210. In the condition of the bridge terminal 210, the upstream and downstream portions of the cable 116 are connected to the bridge terminal 210. The water path in cable 116 becomes discontinuous. Water cannot travel beyond this connection to ECU 102. Therefore, electrochemical corrosion of the PCB 104 is prevented. The bridging terminal 210 or connection prior to the outer casing of the direct plug connector 108 can serve as a maintainable system in which the upstream cable 116 can be replaced if it ages over time due to water present therein. The present invention provides the concept of capillary water in the harness cable 116 of the ECU 102. The present invention provides an anti-intrusion harness for an electronic control unit (ECU) 102.

The specific examples explained in the above description are to be construed as illustrative only and not limiting the scope of the invention. Many of these specific examples, as well as other modifications and variations of the specific examples, are contemplated in the description. The scope of the invention is limited only by the scope of the claims.

Claims (10)

A direct plug connector (108) for an electronic control unit (ECU) (102), the ECU (102) including a printed circuit board (PCB) (104) having a contact pad (120), the direct plug connection The device (108) includes: a plurality of contact terminals (110) configured to pass through the one end cover (112), the plurality of contact terminals (110) being in contact with the contact pads (120) of the ECU (102), and a plurality of cables (116) connected to the plurality of contact terminals (110) by respective strip ends, wherein an insulating material is sealed to the plurality of contact terminals (110) and the plurality of cables A connection between the strip ends of the wire (116). The direct plug connector (108) of claim 1, wherein the insulating material is selected from the group consisting of a potting material (114), a gel, and a heat shrink tubing (304). The direct plug connector (108) of claim 1, wherein the plurality of contact terminals (110) are extended to extend beyond a flexible member (118) but within the end cap (112) And the connection is sealed inside the end cap (112). The direct plug connector (108) of claim 1, wherein the connection comprises a plurality of bridge terminals (210) connecting the strip ends of the plurality of cables (116) to the plurality of contact terminals (110) . The direct plug connector (108) of claim 4, wherein the plurality of bridge terminals (210) are connected to the plurality of contact terminals (110) via a plurality of auxiliary cables (202). The direct plug connector (108) of claim 4, wherein the plurality of bridge terminals (210) are connected to respective ones of the plurality of contact terminals (110) via a single auxiliary cable (302). The direct plug connector (108) of claim 6, wherein the plurality of bridge ends The child is sealed using a heat shrinkable tube member (304). The direct plug connector (108) of claim 7, wherein a gasket (402) is disposed with the plurality of bridge terminals (210) and the plurality of contact terminals (110) together with the heat shrinkable tube members (304) )between. The direct plug connector (108) of claim 4, wherein the plurality of bridge terminals (210) are connected to each of the plurality of contact terminals (110) via a plurality of anti-wool cables (502) . The direct plug connector (108) of claim 9, wherein the plurality of bridge terminals are sealed using a heat shrink tubing (304).