Abstract:
Control modules having connectors with compliant pin terminals for connection to a printed circuit board (PCB) are provided. The module housing can be made of a die cast metal to withstand harsh environments and have at least one open bay area for receiving a connector having compliant pin contacts for connecting the module to a PCB. A plurality of compliant pin terminal can have a push shoulders for providing an engagement surface for insertion of the terminals through passages in a connector housing, for positioning the connector relative to the die cast housing during the mounting the connector to the die cast housing, and to transfer the force away from the connector housing applied in connecting the PCB to the compliant pin tips. The connectors can be linear and exposed terminal surfaces can be sealed against the elements by a sealant. The passages of the connector housing can have at one end of the passages cross shaped portions to allow for a strengthened die tool which forms the small passages and chamfered sides at the opposite end of the passages for tight engagement with the terminals to prevent leak of sealant. The connectors can include a three-pronged compliant pin grounding terminal to increase the current flow.

Description:
[0001]    This application claims priority to U.S. Provisional Application Ser. No. 60/818,091 filed Jun. 30, 2006, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention is directed generally to electronic control modules. More particularly, the present invention is directed to electronic control modules having compliant pin contacts or terminals for interfacing to a printed circuit board (PCB) and methods for manufacturing such control modules. Even more specifically, the invention is directed to a control module having a die cast housing having at least one open bay area for receiving a connector having compliant pin contacts for connecting the module to a PCB. 
         [0003]    Typical die cast modules have wire contacts that require soldering to connect the contacts to the PCB. Soldering is expensive, has the potential for being associated with environmental hazards and is prone to cracking over time. Compliant pin contacts require a straightforward press-fit or interference connection with the PCB. Mounting compliant pin contacts to die cast modules has not been commercially feasible. One difficulty that the present approach has recognized and addressed is a certain level of variability inherent in mass produced die cast housings that prevents the precise placement of the compliant pins needed to achieve proper and consistent operation. Precise placement is a necessity because the PCB connection tip of the compliant pins must be centered in the PCB upon mounting of the PCB to the die cast housing. Another issue involved in providing a integrated control module, i.e. a preassembled control module having compliant pin connectors for later addition of a PCB by the end used, is that each component of the integrated control module introduces variability in the tolerances in the final integrated control module. The relative tight tolerances required in precisely placing compliant pin terminals for mating to a PCB make integrating the compliant pin connector to a control module housing have prevented a viable solution. 
         [0004]    U.S. Pat. No. 6,773,272, which is incorporated herein by reference, discloses a module having two right-angled electrical connectors. The module housing is a box structure assembled of plastic walls. The right-angled connectors are supported by a connector alignment member at the contact mating end and a plastic pin alignment plate having stop shoulders to engage push shoulders on the compliant pin end. The entire force applied to mount PCB to the compliant pin ends is transmitted to the plastic pin alignment plate. 
         [0005]    The present disclosure provides an approach by which a control module having compliant pin connectors can withstand the heat, moisture, and vibration found in difficult environments such as automotive or vehicular applications. In on aspect of the present approach, linear connectors having compliant pin terminals or contacts are precisely and nearly permanently positioned relative to certain reference points on the die cast module housing and in a manner allowing for sealing of exposed terminal portions. In this aspect, push shoulders on the compliant pin terminals are supported independently of the connector or shroud housing and by positioning the terminals by reference to the push shoulders and certain places of the die cast housing reliable electrical engagement with a PCB is assured without risking deformation of the connector and the resulting misalignment of terminals. The present disclosure also provides methods for the production of such control modules. 
       SUMMARY OF THE INVENTION 
       [0006]    In one aspect of the presently disclosed approach, a control module is provided. The control module comprises a module housing having opposing first and second sides and a bay opening therethrough, and a connector extending through the bay and mounted to the module housing. The connector includes a housing having a printed circuit board side and a mating side and a core on the printed circuit board side and a plurality of conductive terminals. The core includes passages having opposing first and second openings. The first opening is positioned at the printed circuit board side of the housing and the second opening is positioned at the mating side of the housing. Each conductive terminal extends through one of the passages and has a compliant pin portion at one end for insertion in a hole in a printed circuit board and a contact portion at an opposite end for insertion in an opening in a complementary connector. The compliant pin portion extends out from the first opening and towards the printed circuit board side and the contact portion extends out from the second opening and towards the mating side of the connector housing. 
         [0007]    In another aspect of the presently disclosed approach, an electrical connector is provided. The electrical connector comprises a housing having a printed circuit board side and a mating side, a core on the printed circuit board side, and a plurality of conductive terminals. The core includes a plurality of passages having opposing first and second openings. Each conductive terminal extends through one of the plurality of passages and has a compliant pin portion at one end for insertion in a hole in a printed circuit board having a predetermined thickness and a contact portion at an opposite end for insertion in an opening in a complementary connector. The compliant pin portion extends out from the first opening and towards the printed circuit board side and the contact portion extends out from the second opening and towards the mating side. 
         [0008]    In another aspect of the presently disclosed approach, a method of making a control module is provided. The method comprises the steps of: providing a control module housing having opposing first and second sides and a bay opening therethrough. The second side includes at least one pad. Providing a connector including a plurality of terminals. Each terminal has a compliant pin portion at one end of the terminal for insertion in a hole in a printed circuit board, a contact portion at an opposite end of the terminal for insertion in an opening in a complementary connector, and a push shoulder therebetween. Each terminal extends through and is secured to one of the passages. Providing an alignment tool including a pin support tower having a top surface and at least one post having a top surface. The top surfaces are vertically spaced apart a predetermined distance X from each other. Placing the connector on the alignment tool wherein the push shoulders are supported on the pin support tower. Mounting the connector to the control module housing including the steps of bringing control module housing and connector together such that the connector passes through bay and at least one pad contacts at least one post. 
         [0009]    Other aspects, objects and advantages of the present invention will be understood from the following description according to the preferred embodiments of the present invention, specifically including stated and unstated combinations of the various features which are described herein and relevant information which is shown in the accompanying drawings and examples. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of one embodiment of a compliant pin control module according to the present invention. 
           [0011]      FIG. 2  is a perspective view of the mating side of the control module housing shown in  FIG. 1  having three empty bays, each of which can receive compliant pin connectors. 
           [0012]      FIG. 3  is a perspective view of the printed circuit board side of the control module housing shown in  FIG. 2 . 
           [0013]      FIG. 4  is a perspective view of the right side of one embodiment of a connector or shroud assembly of the present invention having a portion of the shroud housing cut away. 
           [0014]      FIG. 5  is an elevation view of a cross-section of the compliant pin control module shown in  FIG. 1  showing the shroud assembly mounted to the control module housing. 
           [0015]      FIG. 6  is a perspective view of the left hand side of the shroud assembly shown in  FIG. 4 . 
           [0016]      FIG. 7  is a perspective view of one embodiment of the PCB side of a shroud housing of the present invention. 
           [0017]      FIG. 8  is a perspective view of one embodiment of a compliant pin terminal of the present invention. 
           [0018]      FIG. 9  is a front elevation view of the compliant pin shown in  FIG. 8   
           [0019]      FIG. 10  is a side elevation view of the compliant pin terminal shown in  FIG. 8 . 
           [0020]      FIG. 11  is a front elevation view of one embodiment of a three-prong U-shaped compliant pin grounding terminal of the present invention. 
           [0021]      FIG. 12  is a side elevation view of the compliant pin grounding terminal shown in  FIG. 11 . 
           [0022]      FIG. 13  is  FIG. 8  is a perspective view of the compliant pin grounding terminal shown in  FIG. 11 . 
           [0023]      FIG. 13   a  is a plan view representation of one embodiment of a three-prong U-shaped compliant pin grounding terminal of the present invention. 
           [0024]      FIG. 13   b  is a plan view of one embodiment of a three-prong L-shaped compliant pin grounding terminal of the present invention. 
           [0025]      FIG. 14  is a perspective view of another embodiment of a three-prong U-shaped compliant pin grounding terminal of the present invention. 
           [0026]      FIG. 15  is an elevation view of the mating side of the shroud housing shown in  FIG. 7 . 
           [0027]      FIG. 16  is an elevation view of a cross-section of a portion of shroud assembly of the present invention showing compliant pin terminals in the compliant pin openings or passages and a three-prong U-shaped grounding terminal in a grounding pin opening or passage. 
           [0028]      FIG. 17  is an elevation view of a cross-section of another embodiment of a compliant pin control module of the present invention showing the vertical distance between the shroud face and the push shoulders of the compliant pin terminals. 
           [0029]      FIG. 18  is a perspective view of one embodiment of an alignment tool of the present invention. 
           [0030]      FIG. 19  is an elevation view of the cross-section of the compliant pin control module shown in  FIG. 17  showing the vertical distance between the push shoulder of the compliant pin terminal and the pad of control module housing, the vertical distance between the pad of control module housing and the PCB ledge, and the thickness of a PCB seated on PCB ledge. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriate manner. 
         [0032]      FIG. 1  illustrates one embodiment of compliant pin control module  10  of the present invention. A housing  12  shown in  FIG. 2  has three bays  14 ,  16 ,  18  for receiving respective connectors  20 ,  22 ,  24  each of which can have numerous compliant pin terminals or contacts  21  as shown in  FIG. 1 . Control module housing  12  can be molded plastic or die cast from metal or from a metal alloy and thus made relatively inexpensively. They can be made of any metal or plastic suitable for the intended end use. Often aluminum and/or aluminum containing alloys will be used. The control module housing can have one or more bays for receiving connectors depending on the application. For example, three connectors  20 ,  22 ,  24  which also are known as compliant pin shroud assemblies, are shown in  FIG. 1 . While from time to time three connector systems are shown and described herein for illustrative purposes it will be understood that less than or greater than three connectors are intended. 
         [0033]    Mating side  26  of housing  12  shown in  FIGS. 1 and 2  is so named to refer to the side on which complementary connectors (not shown) will mate with connectors  20 ,  22 ,  24 . Each also has a PCB side  28  shown in  FIG. 3  which is the side of the housing  12  where a PCB can be mounted. Mating side  26  can have a set of fins (not shown) for heat dissipation, and each of bays  14 ,  16 ,  18  can have a rib  32 ,  34 ,  36  respectively encircling the bay and extending up from side  26  of housing  12  for mounting a shroud assembly to housing  12 , which will be discussed in more detail below. Mating side  26  can also have four pads  38  near each corner of the housing, if applicable. Pads  38  generally reside on the same plane which is substantially perpendicular to sides  42  of module housing  12 . Pads  38  can serve as reference points for the precise placement of compliant pin terminals  21  relative to housing  12  via precise placement of one or more shroud assemblies. In particular, pads  38  allow precise placement of compliant pin terminals  21  at the chosen vertical height in module housing  12  by spacing the compliant pin terminals  21  at a certain position, such as push shoulders discussed below, a predetermined vertical distance from the pads  38 . Since pads  38  are maintained or machined to be a set predetermined vertical distance from the PCB ledge  40 , precise placement of the compliant pins  21  is attained. 
         [0034]    PCB side  28  can have PCB ledge support  40  around housing  12 . PCB ledge support can also serve to provide reference points for the precise placement of compliant pins  21  via precise placement of one or more shroud assemblies. 
         [0035]    Moving now to the connectors or shroud assemblies that can be mounted on the control module, it can be seen that control module  10  has three connectors or shroud assemblies  20 ,  22 ,  24 . The shroud assemblies can be designed to have a variety in number and arrangement of compliant pins  21 . As shown in  FIG. 1  shroud assembly  20  is a 56-Way compliant pin shroud assembly having fifty-six compliant pins  21 , and shroud assemblies  22 ,  24  are 73-Way compliant pin shroud assemblies each have seventy-two compliant pin terminals  21  and one three-pronged compliant pin grounding terminal  23 . 
         [0036]    Even though both shroud assemblies  22 ,  24  have the same number of compliant pin terminals  21  and compliant pin grounding terminal  23 , the keying structures for each shroud housing can be different. The description that follows for shroud assembly  22  is for a shroud housing having particular mating structures for a specific use, and it will be appreciated that other mating structures may be provided that vary from application to application. Otherwise the description is also equally applicable to shroud assemblies  20 ,  24  except that shroud assembly  20  has a different number of compliant pin terminals  21  and lacks a three-pronged compliant pin grounding terminal  23 . Both can have different shroud housing keying structures. 
         [0037]    As shown in  FIG. 4 , shroud assembly  22  can have shroud housing  54 , compliant pin terminals  21 , three-prong compliant pin grounding terminal  23  and pin alignment plate  56 . Housing  54  can be made of a dielectric such as plastic or other such material and can be made using any known manufacturing technique, such as injection molding. Housing  54  can have a skirt  60  positioned on mating side  62  of the shroud assembly  22  and ending at skirt face  55 . Core  64  in which compliant pin terminals  21  extend through is positioned on PCB side  66  of shroud assembly  22 . A tongue  68  is centrally located in the cavity defined by skirt  60  and can have a slot  70  separating tongue  68  into two sections. Surrounding core  64  is channel or groove  72 . As shown in  FIG. 5 , channel  72  can receive rib  34  of housing bay  16  and an amount of adhesive  74  to mount shroud assembly  22  to die cast housing  12 . The other illustrated shroud assemblies  20  and  24  can be mounted in the same manner. 
         [0038]    Each of two opposing walls  76 ,  78  ( FIG. 6 ) of skirt  60  run parallel with mating alignment tongue  68  and can include two wide posts  80 ,  82  adjacent the corners of skirt  60  and two thinner posts  84 ,  86  between wide posts  80 ,  82  as shown in  FIG. 6 . Mating alignment tongue  68  assists in keeping shroud assembly  22  and a complementary connector properly aligned to prevent damaging compliant pin terminals  21 . Each wide post  80 ,  82  can have knob  88  and each thin post  84 ,  86  can have button  90  extending perpendicular from, skirt  60  toward the exterior of the shroud assembly  22 . A ledge  92  extends perpendicular from skirt  60  towards the exterior of the shroud assembly  22  and surrounds the skirt  60  except for interruptions at the base of posts  80 ,  82 ,  84 ,  86 . A mating connector (not shown) has complementary structures for interference type locking with the mating side  62  of shroud assembly  22  which preferably results in a water resistant connection. 
         [0039]    Core  64  on the PCB side  66  of shroud housing  54  shown in  FIG. 7  can have a raised platform  94 . Raised platform  94  can have two pin blocks  96 ,  98  separated by channel  100 . Each pin block  96 ,  98  can have multiple pin passages or openings  110  arranged in two rows to accept compliant pins  21  therethrough. One or more larger pin openings may be needed depending on the type of compliant grounding pin if any is utilized. Inner sidewalls  102 ,  104  that form channel  100  can be wavy or undulating as opposed to flat as can outer sidewalls  106 ,  108  which are opposite to inner sidewalls  102 ,  104 . These wavy surfaces can reduce air bubble formation if an elastomeric sealant is applied on the PCB side of die cast housing bay. Even small air pockets can expand during a heating or curing process of an elastomeric sealant so any reduction in air entrapment is advantageous. Also, as shown in  FIG. 7 , the peaks of the individual wave surface can be in alignment with pin openings  110  and provide reinforcement of the sidewall at the pin opening position. 
         [0040]    As shown in  FIG. 5 , elastomeric sealant  112  can be used to fill flood area on PCB side  28  of bay  16  up to a level just below pin alignment plate  56  to cover what would otherwise be exposed surfaces of the terminals  21  after one side of shroud assembly is connected to PCB and complementary connectors are connected to the other side of the shroud assembly. Sealant  112  can be any polymer or polymer system that will provide needed assembly characteristics, typically upon curing such as heat curing. Such polymers or polymer systems should be resistant to vibration, temperature fluctuation and moisture depending on the environment the control module will be exposed to. A typical sealant is a silicone polymer but others such as urethane based, epoxy or plastic polymers can be used. Sealant  112  seals the pin openings  110 , gap  114  between the dies cast housing  12  and shroud assembly  22  and also can reinforce and/or protect adhesive  74 . 
         [0041]    One embodiment of compliant pin terminal  21  is shown in  FIGS. 8 ,  9  and  10 . Compliant pin terminals are formed of a conductive material and while compliant pin terminals can have any number of size and shape configurations such as linear or right angled, one common feature is a compliant pin tip  116 . Tip  116  has a central elongated opening  118  that permits the pear-shaped or spear-shaped body  120  to contract radially to permit tip  116  to be inserted into an opening  124  in the PCB  126  shown in  FIG. 5 . Opening  124  extends through entire thickness of PCB  126 . Opposite tip  116  is mating bar  128 . In the embodiment of a compliant pin shown in  FIGS. 8-10  the mating bar has a square cross-section having 0.64 mm sides. Mating bar  128  makes electrical contact with a complementary connector and can have a tapered contact end  122 . Shaft  130  extends between tip  116  and bar  128 . At the interface of mating bar  128  and shaft  130  is push shoulder  132 . Shaft  130  can taper inwardly to form throat  134  at the interface with tip  116 . In addition, shaft  130  can be tapered such that the width at push shoulder  132  is greater than the width of shaft end  135 . 
         [0042]    At the base of shaft  130  adjacent push shoulder  132 , the shaft  130  may have a pair of base barbs  136 ,  138 . Each of base barbs  136 ,  138  can extend out an equal distance on opposite sides of shaft  130  and beyond the width of the base of shaft  130  at push shoulder  132 . Further along the shaft  130  towards the tip  116 , shaft  130  can have a pair of leading barbs  140 ,  142  that extend out on opposite sides of shaft  130 . Each of leading barbs  140 ,  142  can extend an equal distance beyond the width of the base of shaft  130  but not a far as base barbs  136 ,  138 . Since compliant pin terminal  21  are inserted tip  116  first through pin opening  110  on mating side  62  of shroud housing  54 , leading barbs  140 ,  142  are the first to contact inner walls  113  (shown in  FIG. 16 ). Having the leading barbs not extend out from the sides of shaft  130  as much as base barbs  136 ,  138  prevents pin opening  110  from being deflected open to such a degree that base barbs  136 ,  138  may not properly or sufficiently engage inner walls  113 . In other words, having the leading barbs  140 ,  142  not extend out from the sides of shaft  130  as far out as base barbs  136 ,  138  allows both sets, leading barbs  140 ,  142  and base barbs  136 ,  138  to sufficiently engage inner walls  113  and to securely retain compliant pin terminals  21  within pin openings  110 . 
         [0043]    Shaft  130  can also include two pairs of spaced apart carrier tabs  144 ,  146 ,  148 ,  150 . Each pair of carrier tabs  144 ,  146 ,  148 ,  150  extend out an equal distance on opposite sides of the shaft  130  a distance less than that of the leading barbs  140 ,  142 . The size and shape of the carrier tabs usually is determined by severance of the pin terminals from a carrier member having a plurality of pins extending therefrom, such carrier arrangements being generally known for simultaneous multiple placement of pins. 
         [0044]    The edges  141 ,  143  closest to tip  116  can intersect with respective edges  145 ,  147  at an obtuse angle. This obtuse angle of the leading barbs  140 ,  142  allows for spacing between leading barbs  140 ,  142  and chamfered ends of pin openings  110  which will be discussed in more detail below. This spacing provides collection volume for shroud housing debris from the inner walls  113  of pin openings  110  that can be shaved off by leading barbs  140 ,  142  and that could otherwise prevent the full seating of compliant pin terminal  21  in pin opening  110 . 
         [0045]    In the embodiment shown in  FIGS. 8-10 , compliant pin terminal  21  is stamped from a brass alloy sheet metal having a thickness of about 0.64 mm. The length from end of tapered end  122  to end of tip  116  can be about 25 mm to about 30 mm. The width at push shoulder  132  can be between about 1.5 mm and about 2 mm and the length from push shoulder  132  to end of tip  116  can be from about 18 mm to about 20 mm, for example. Leading retention barbs  140 ,  142  can extend out from their intersection with shaft  130  about 0.3 mm and base barbs can extend out from their intersection from shaft about 0.4 mm. Tip  116  can be tin plated and bar  128  can be gold plated. A series of compliant pins  21  can be stamped as a strip of compliant pins  21  joined at carrier tabs. A stitching machine (not shown) can shear the compliant pin from the strip and insert it into pin openings  110 . 
         [0046]    One embodiment of a compliant pin grounding terminal can have a three-prong structure. Three-prong compliant pin grounding terminal  23  is shown in  FIGS. 11-13 . It is noted that grounding can be accomplished with a compliant pin terminal such as compliant pin terminal  21 . Compliant pin terminal  21  can safely handle about 5 amps of current. Three-prong compliant pin grounding terminal  23  can safely handle about 24 amps of current. Grounding terminal  23  can have a mating blade  152  for contacting a complementary connector (not shown). Terminal blade end  154  can be tapered inwardly. Cross member  156  can extend at a right angle to blade  152 . The blade-side surface of cross member  156  forms push shoulder  157 . 
         [0047]    Extending from a center portion  158  and end portions  160 ,  162  of cross member  156  in a direction opposite blade  152  can be central shaft  164 , and end shafts  166 ,  168  respectively. At the ends of shafts  164 ,  166 ,  168  are PCB tips  170 ,  172 ,  174  respectively that have a pear-shaped or spear-shaped bodies  176 ,  178 ,  180  and centrally located elongated opening  182 ,  184 ,  186 . Cross member  156  shown in  FIGS. 11-13  has two radiused right angle bends  188 ,  190 , bending in the same direction such that cross member ends  160 ,  162 , end shafts  166 ,  168  and PCB tips  172 ,  174  lay on respective planes generally perpendicular to the plane of the blade to form a U-shape such as shown in representational drawing  13   a . Alternatively, only one of cross member ends  158 ,  160  can be bent at a right angle in a plane perpendicular to the plane of blade  152  to form an L-shape such as shown in representational drawing  13   b . The L-shape configuration reduces the amount of heat build up at the tips and shafts as compared to a three prong terminal having its tips, shafts and cross-member laying on the same plane but does not reduce heat build up as efficiently as the U-shape configuration. 
         [0048]    Heat buildup, which reduces current flow through the grounding terminal, is reduced by increasing the spacing between the shafts of the terminal. An illustration of this concept is shown in cross-sectional representation of a U-shaped three-prong grounding terminal shown in  FIG. 13   a  and an L-shaped three-prong grounding terminal  13   b . Rectangle “R” represents the cross-section of shafts of grounding pin terminal, and circles “C” represent heat radiating from shafts “R”. Intersecting circles are areas of heat build up. As is evident in  FIGS. 13   a  and  13   b , the spacing among all of the shafts “R” is greater for the U-shape than for the L-shape while both exhibit shaft spacing (given some terminal dimensions) than an in-line or linear orientation of the shafts “R”. 
         [0049]    Referring back to  FIGS. 11-13 , central shaft  164  can have a pair of aligned and opposing retention barbs  192 ,  194  located adjacent central portion  158  of cross member  156 . End shafts  166 ,  168  can also include retention barbs  196 ,  198  at a position aligned with retention barbs  192 ,  194  and cross member ends  160 ,  162  can also include retention barbs  200 ,  202  at an end closest to blade  152 . Retention barbs  196 ,  198 ,  200 ,  202  extend in the same direction. Retention barbs  192 ,  194 ,  196 ,  198 ,  200 ,  202  help to retain ground pin  23  in ground pin opening. 
         [0050]    Three-prong grounding pin  23   a  shown in  FIG. 14  is similar to three-prong grounding pin  23  in all respects except that blade  152   a  includes a pair of aligned and opposing carrier tabs  204 ,  206 . As with compliant pin  21  discussed above, carrier tabs  204 ,  206  permit three-prong grounding pin  23   a  to be provided on a continuous strip of grounding pins  23   a  joined at carrier tabs  204 ,  206 . In one embodiment, grounding pins  23 ,  23   a  can be stamped from 0.80 mm thick brass alloy sheet metal, and the end tips  170 ,  172 ,  174  can be tin-plated. The blade  152  can have a width of 2.8 mm. Spacing between the centers of end tips  172 ,  174  can be 5.68 mm and the spacing from either end tip  172 ,  174  to center tip  170  can be 2.84 mm. In one embodiment grounding pin  23  can have a length of about 30 mm measured from tapered end  154  to end of tip  170 . The length from end of tip  172  to its respective push shoulder  157  can be about 18 mm to about 20 mm, which can be the same for the other two prongs of grounding pin  23 . The width across push shoulder  157  can be about 6 mm. Retention barbs  192 ,  194  can extend out from their respective points of intersection with shaft  164  about 0.4 mm to about 0.5 mm. Retention barbs  196 ,  198 ,  200 ,  202  can extend out from their respective points of intersection with respective shafts  166 ,  168  about 0.4 mm to about 0.5 mm. 
         [0051]    Pin openings  110  have PCB side opening  208  and mating side opening  210  as best shown in  FIG. 5 . Mating side opening  210  can have a “plus” shape or cross shape as shown in  FIG. 15 . Corner blocks  212  that define the plus-shaped mating opening  210  are square and can have a raised diagonal ridge line  214  with opposing halves  216  that slope downwards towards the PCB side opening  208 . This helps to reduce points of stress on the housing at openings  210 . One cross-member portion  218  of opening  110  can extend completely through to the PCB side opening  208 . The other perpendicular cross-member portion  220  can extend only a partial distance towards PCB side opening  208 . One benefit of plus-shaped mating opening  210  is that the portion of the die tool or the post of the mold that forms opening  110  has added structural support which can be helpful in resisting breakage of the die tool in view of the small dimensions of pin openings  110 . A benefit of extending cross-member  220  only partially towards the PCB side opening  208  that sealant  112  shown in  FIG. 5  does not leak through or is able to bridge any gaps before significant leakage to mating side  64  of shroud housing  54  occurs. 
         [0052]    Cross-member portion  218  of opening  110  can neck inward or have chamfered sides  222  to narrow the PCB-side opening  210  so as to snugly fit the width of shaft  130  as best shown in  FIG. 16 . The chamfered sides  222  help guide pin  21  through opening  110  and form pockets  224  with leading barbs  140 ,  142 . Opening  110  has a width slightly less than the width of pin  21  taken at the farthest extents of leading barbs  140 ,  142  and slightly larger than the base measured across push shoulders  132 . Because pin opening  110  is narrower than leading barbs  140 ,  142  shavings can be created as pin  21  is inserted through opening  210 . Pockets  224  can receive any such shavings which could otherwise prevent pin  21  from proper seating in pin opening  21 . 
         [0053]      FIGS. 4 and 16  also show one embodiment of grounding pin opening  226  for U-shaped three-prong grounding pin  23 . As shown in  FIG. 4 , ground pin opening  226  on the mating side  62  can have a U-shape for accepting cross-member  158 . On the PCB side  66  are three separate slot openings to accept each shaft  164 ,  166 ,  168 . Retention barbs  192 ,  194 ,  196 ,  198 ,  200 ,  202  engage the inner walls to secure and align grounding pin  23  in grounding pin opening  226 . 
         [0054]    The assembly process of control module  10  typically includes metal casting of die cast housing  12 . Die cast housing  12  is cast from aluminum but other metals or alloys can be used as noted herein. As shown in  FIGS. 1 and 2 , die cast housing  12  can have pads  38  which can be machined to obtain a flat top surface. Flat surface at each pad  38  provides a stable support for accurate and precise placement of one or more shroud assemblies  20 ,  22 ,  24 . Precise and accurate placement of shroud assemblies  20 ,  22 ,  24  relative to the die cast housing  12  translates to precise and accurate positioning of compliant pin terminals  21  and ground terminal  23  if used. Without accurate and precise positioning of compliant pin terminals, PCB may not properly mate with and/or form complete electrical contact with the pin terminals. In addition to obtaining a flat surface, the vertical distance between PCB support ledge  40  and each pad is measured. If the any of the vertical distances are not within specified tolerances, the pad or pads  38  may be machined further to obtain the proper spacing between each pad  38  and PCB support ledge  40 . This verification of spacing is results from the inherent variability in die casting of the module housing  12 . 
         [0055]    Shroud housing  54  can be made of plastic in many ways such as mold injection methods. Shroud housing  54  can then proceed to a stitching operation. A rolled up strip of compliant pins  21  (not shown) can be loaded into a stitching machine (not shown) of a type known in the art which singulates or separates a compliant pin  21  from the strip and pushes each pin  21  (tip  116  end) first using push shoulder  132  through mating side opening  210 . The stitching machine is set to insert each compliant pin  21   a  set distance which can be short of the final seating position of the pin. If any additional grounding pin  23  is required it can be inserted in the same or similar manner. 
         [0056]    Shroud housing  54  having pins  21  and grounding pin  23  inserted into pin openings  110 , and grounding pin opening  226 , respectively is placed on a nest (not shown). The nest can have a series of pin supports (such as pin support towers  230  of alignment tool  228  discussed below) to support push shoulders  132  of pins  21  and  157  of grounding pin  23 . The nest can also include a shroud housing support that is placed a predetermined distance “A” from the pin supports. The predetermined distance “A” is the vertical distance from the pin supports to the shroud housing support. In one embodiment the predetermined distance is about 17.3 mm. Shroud housing  54  can then be pushed against the nest until skirt face  55  contacts shroud housing support which causes compliant pins  21  and grounding pin  23  to be pushed further into pin openings  110  and grounding pin opening  226  respectively. Predetermined distance “A” is duplicated to the partially finished shroud assembly such that compliant pin push shoulders  132  and grounding pin shoulder  157  are spaced predetermined distance “A” from skirt face  55  as shown in  FIG. 17 . 
         [0057]    While still on the nest, pin alignment plate  56  can then be mounted to compliant pins  21 . The nest prevent compliant pins  21  and grounding pin  23  from being push out of position in openings  110  and  226  respectively. Pin alignment plate  56  is held in place by friction as the openings in the pin alignment plate  56  closely match the dimensions of pins  21  and grounding pin  23 . The compliant pin terminals and grounding pins are retained in their respective passages or openings by their respective retention barbs and not by the push shoulders. The same steps can be performed to produce additional shroud assemblies. The next step is the mounting of a shroud assembly to the die cast housing. 
         [0058]    The mounting of one shroud assembly will be described below but which is applicable to the mounting of more than one shroud assembly to a die cast housing. 
         [0059]    Alignment tool  228  shown in  FIG. 18  can be used to position shroud assembly  22  relative to die cast housing  12  during the mounting process. Alignment tool  228  can have one or more pin support towers  230  depending on the number of shroud assemblies to be mounted. Each pin support tower can have a row of fingers  232  wide enough to support two rows of compliant pins  21  at their push shoulders  132 . Since shroud housing  54  of shroud assembly  22  has two pin blocks  96 ,  98  and each pin block  96 ,  98  has two rows of pin openings  21  as shown in  FIG. 7 , two rows of fingers  232  are provided. The fingers  234  are spaced apart to accommodate the mating bars  128  of compliant pins  21 . Since there are 20 compliant pins per row of openings  110  as shown in  FIG. 6  twenty one fingers  234  are included to provide twenty spaces  236 , one for each pin  21 . Second row of fingers  238  that includes wider fingers  239  is configured to support the two rows of sixteen pins  21  and a three-pronged grounding  23  at their respective push shoulders  132 ,  157  of shroud assembly  22  partially shown in  FIGS. 1 and 4 . 
         [0060]    Posts  240  included in alignment tool  228  have top surfaces  242  set a predetermined distance “B” from the top surfaces  244  of fingers  234 . Predetermined distance “B” is the vertical distance from top surface  244  of fingers  234  to top surface  242  of posts  240 . In one embodiment, predetermined distance “B” can be about 1.61 mm. 
         [0061]    Adhesive  74  is dispensed in groove  72  as shown in  FIG. 5 . The adhesive can be silicone based adhesive but could also be an epoxy or ceramic cement compound. Shroud assembly  22  is placed on support tower  230  so that push shoulders  132  contact top surfaces  244  of fingers  234 . Die cast housing  12  is placed over shroud assembly  22  and rib  34  of bay  16  (see  FIG. 2 ) is positioned in groove  72  and pads  38  are positioned over posts  240 . Orientation rods interface with cavities  245  shown in  FIG. 1  to assist in orienting control module housing  12  to alignment tool  228 . Die cast housing  12  is lowered onto alignment toll  228  so that shroud assembly passes through bay  16  and until die cast housing contacts or engages alignment tool  228  so that pads  38  contact posts  240 . The die cast housing is retained in this position as the adhesive is cured typically through heat treatment. When the curing process is over and shroud assembly  22  is fixed to die cast housing  12 , predetermined distance “B” is consequently duplicated such that the vertical distance from push shoulders  132  to any of pads  38  is predetermined distance “B” as shown in  FIG. 19 . 
         [0062]    As shown in  FIG. 19 , three other measurements can affect the accurate and precise placement of compliant pins  21  relative to die cast housing  12  to ensure pin tips  116  make a complete seating and proper electrical connection to PCB  126 . Predetermined distance “C” is the vertical distance from push shoulder  132  to the center of elongated opening  118  of compliant pin tip  116 . In one embodiment, predetermined distance “C” can be about 16.4 mm. Predetermined distance “D” is the vertical distance from pad  38  to PCB support ledge  40 . In one embodiment, predetermined distance “D” can be about 14.0 mm. Predetermined distance “E” is the vertical distance from PCB support ledge  40  to center of elongated opening  18  of compliant pin tip  116 . Although not shown to scale in  FIG. 19 , the thickness of PCB  126  is twice predetermined distance “E”. In one embodiment, predetermined distance “E” can be about 0.79 mm and PCB thickness can be 1.58 mm. Alteration of any of predetermined distances A-E can result in altering the remaining predetermined distances. 
         [0063]    Once one or more shroud assemblies are mounted to the control module housing, a PCB is ready to be mounted to the control module. The force required to mount the PCB to the control module varies with the number of total compliant pins in the module. For a control module such as control module  10  shown in  FIG. 1 , three thousand pounds of pressure may be necessary to force the tips of compliant pin terminal through holes in the PCB. It is preferably to prevent this force from being applied to the shroud assembly especially if the shroud housing is made of plastic to avoid deformation of the shroud housing and possible resulting movement of the terminals. A PCB assembly tool similar to alignment tool  228  is utilized to support compliant pin terminals and grounding terminals at their respective push shoulders instead of having supports in the shroud housing that engage the push shoulders since this could result in the above issues. 
         [0064]    While the present invention has been described in detail with reference to the foregoing embodiments, other changes and modifications may still be made without departing from the spirit or scope of the present invention. It is understood that the present invention is not to be limited by the embodiments described herein. Indeed, the true measure of the scope of the present invention is defined by the appended claims including the full range of equivalents given to each element of each claim.