Abstract:
A pin terminal alignment system which serves to fix pin terminal spacing, provide indexable spacing and provide ease of installation. A pair of alignment bodies, each having a generally planar, elongated shape and preferably formed of plastic, each have a plurality of alignment holes formed therein, wherein each alignment hole is allocated to a respective pin terminal of a header assembly. The system preferably includes an abutting interaction between the alignment bodies and the header assembly which indexably spaces the bodies with respect to the header assembly, as well as with respect to a printed circuit board to the pin terminals connect. The rigidity and locating features provided by the terminal pin alignment system serve to ensure geometrical dimension and tolerance precision of the pins as a whole, and the pin terminals in particular, with respect to both the header assembly and the PCB.

Description:
TECHNICAL FIELD 
     The present invention relates to connection modalities between the pin terminals of a header assembly and a printed circuit board (PCB), and more particularly to pin alignment devices for the pin terminals. Still more particularly, the present invention relates to a rigid pin terminal alignment system which provides precise pin terminal alignment and indexable spacing features. 
     BACKGROUND OF THE INVENTION 
     As shown at FIG. 1, a header assembly  10  is used to interconnect between wiring harness connectors and a printed circuit board (PCB) (not shown). The header assembly  10  is typically constructed of aluminum and has four receptacles, arranged as an upper left receptacle  12 , a lower left receptacle  14 , and upper right receptacle  16  and a lower right receptacle  18 . Within each receptacle of the header assembly  10 , a plurality of pins  20  are affixed by a plastic inset and epoxy as an upper row and a lower row, wherein the upper and lower rows of pins of each receptacle provide a bank of pins particular to that receptacle. For example, given that the upper and lower rows each have twenty pins, then each receptacle has a bank of forty pins. The receptacles receive, respectively, a corresponding connector of one or more wiring harnesses so as to electrically contact the pins. At the rear side of the header assembly  10 , the pins  20  horizontally project to a predetermined bend location respectively for each of the upper and lower rows of each of the receptacles, respectively, whereupon the pins are vertically oriented and terminate as pin terminals  22  at a common plane. 
     Problematically, the pin terminals  22  of the pins  20  are distantly separated from the header assembly  10 , resulting in the precise alignment of the pin terminals being subject to misalignment with the application thereto of lateral forces. However, in order for the pin terminals  22  to properly interface with corresponding connection locations of a PCB, it is necessary to restrain the pin terminals from being free to move relative to one another so that pin terminal alignment will remain precise. 
     In the prior art, it is known to utilize a perforated mylar sheet  24  to restrain movement of the pin terminals, wherein each pin terminal passes through a respective perforation  26 . In this regard, a first mylar sheet is used to alignably interface with the two banks of pin terminals associated with the upper and lower left receptacles  12 ,  14 , and a second mylar sheet is used to alignably interface with the two banks of pin terminals associated with each of the upper and lower right receptacles  16 ,  18 . 
     While the mylar sheets can aid to restrain the pin terminals from relatively moving, the inherent flexibility of a mylar sheet cannot prevent an untoward force from misaligning the pin terminals, whether individually, collectively, or as a bank. Further, the need to precisely align the perforations with each respective pin terminal prior to placement of the mylar sheets onto the pin terminals is an undesirably critical assembly step. Further, mylar sheets cannot serve to space the pins with respect to the header assembly and to the PCB. Yet another problem of mylar sheet is that it can slip up the pins or down and off the pins, since it has no ability to indexably space itself relative to the header assembly. Still further, mylar sheets become increasingly incapable of serving their intended pin spacing maintenance function in high pin density applications in which the spacing between the pins is very small. 
     Accordingly, what remains needed in the art is a pin terminal alignment article which serves to fix pin terminal spacing, provide indexable spacing and provide ease of installation. 
     SUMMARY OF THE INVENTION 
     The present invention is a pin terminal alignment system which serves to fix pin terminal spacing, provide indexable spacing and provide ease of installation. 
     The pin terminal alignment system according to the present invention includes a pair of alignment bodies, each having a generally planar, elongated shape and preferably formed of plastic. Each alignment body has a plurality of alignment holes formed therein, each alignment hole being allocated to a respective pin terminal of a header assembly. The system preferably includes an abutting interaction between the alignment bodies and the header assembly which indexably spaces the bodies with respect to the header assembly. 
     At a top side of each alignment body, the alignment holes are each provided with a guide cone for providing guided pin insertion into the alignment holes without risk of pin distortion, even where the insertion operation is performed manually. A pair of header index spacers are provided on both of the alignment bodies which indexably interface with the header assembly to provide precise location of the alignment bodies with respect to the header assembly, and as an inherent consequence thereof, precise geometrical dimension and tolerance of the pin terminals with respect to the header assembly and the PCB to which the terminals pins are to be electrically connected. A PCB index leg on one of the alignment bodies provides an indexable interface with a PCB so as to ensure a proper interfit between parts. Stand-offs are provided on the bottom side of both of the alignment bodies to ensure a predetermined minimum spacing between the PCB and the alignment bodies, thereby preventing the alignment bodies from resting upon solder joints of the PCB and ensuring prevention of entrapped moisture therebetween. 
     The rigidity and locating features provided by the terminal pin alignment system serve to ensure geometrical dimension and tolerance precision of the pins as a whole, and the pin terminals in particular, with respect to both the header assembly and the PCB. 
     Accordingly, it is an object of the present invention to provide a pin terminal alignment system which rigidly aligns the pin terminals in a predetermined arrangement prior to connection to a PCB. 
     It is an additional object of the present invention to provide a pin terminal alignment system as aforementioned, further featuring rigid alignment bodies having alignment holes for retaining the pin terminals in a predetermined pattern. 
     It is another object of the present invention to provide a pin terminal alignment system as aforementioned, further featuring guide cones at each alignment hole for guiding initial entry of each pin terminal into its respective alignment hole. 
     It is an additional object of the present invention to provide a pin terminal alignment system as aforementioned, further featuring indexable location features with respect to the alignment bodies and the header assembly and selectively with respect to the PCB. 
     It is yet another object of the present invention to provide a pin terminal alignment article as aforementioned, further featuring stand-off features with respect to the PCB. 
     These, and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a prior art header assembly, showing a portion of its associated pin terminals, and a prior art mylar sheet for aligning the pin terminals thereof. 
     FIG. 2 is a perspective view of the terminal pin alignment system according to the present invention, wherein a portion of the pin terminals of a header assembly according to the present invention is shown alignably interfaced with a first alignment body according to the present invention. 
     FIG. 3 is a top perspective view of the first alignment body according to the present invention. 
     FIG. 4 is a bottom perspective view of the first alignment body of FIG.  3 . 
     FIG. 5 is a top perspective view of a second alignment body according to the present invention. 
     FIG. 6 is a bottom perspective view of the second alignment body of FIG.  5 . 
     FIG. 7 is an end view of the terminal pin alignment system, showing the first alignment body operatively interfaced with the header assembly as in FIG.  2 . 
     FIG. 8 is a bottom plan view of the pin terminal alignment system, showing the first and second alignment bodies operatively interfaced with the header assembly. 
     FIG. 9 is a rear view of the pin terminal alignment system, showing the first and second alignment bodies operatively interfaced with the header assembly and a PCB. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the Drawings, FIGS. 2 through 9 generally depict various aspects the pin terminal alignment system  100  according to the present invention. As can be seen by simultaneous reference to FIGS. 2,  7 ,  8  and  9 , the pin terminal alignment system  100  provides precise geometrical dimension and tolerance precision of the pin terminals  102  of a header assembly  104  with respect thereto and to a PCB  106 . In this regard, rigid first and second alignment bodies  108 ,  108 ′, preferably composed of plastic, have a plurality of alignment holes  110  through which the pin terminals  102  alignably pass, the predetermined precise arrangement of the pin terminals being maintained by the pattern of the alignment holes of the first and second alignment bodies. As can be further operationally discerned from FIGS. 7 and 9, the pin terminals  102  project outwardly from the alignment bodies  108 ,  108 ′ so as to provide adequate exposure for connection to the PCB  106 , such as for example by entry into pin receiving holes  106   a  of the PCB and connection thereto by solder (see FIG.  9 ). 
     The header assembly  104  according to the present invention, like the conventional header assembly  10  shown at FIG. 1, has an upper left receptacle  112 , a lower left receptacle  114 , an upper right receptacle  116  and a lower right receptacle  118 . As in the header assembly  10  depicted at FIG. 1, within each receptacle of the header assembly  104 , a plurality of pins  120  are affixed by a plastic inset and epoxy as an upper row  122  and a lower row  124  (see FIG.  7 ), wherein the upper and lower rows of pins of each receptacle provide a bank of terminal pins particular to that receptacle (see FIG.  8 ). Thus, the upper left receptacle  112  has uniquely associated with it a first terminal pin bank  112   p , the lower left receptacle  114  has uniquely associated with it a second terminal pin bank  114   p , the upper right receptacle  116  has uniquely associated with it a third terminal pin bank  116   p , and the lower right receptacle  118  has uniquely associated with it a fourth terminal pin bank  118   p  (see FIG.  8 ). The receptacles  112 ,  114 ,  116 ,  118  operate conventionally with respect to one or more wiring harnesses as described with respect to FIG.  1 . At the rear side  126  of the header assembly  104 , the pins  120  horizontally project (that is, are oriented normal to the rear side  126 ) to a predetermined bend location respectively for each of the upper and lower rows of each of the receptacles, respectively, whereupon the pins  120  are vertically oriented (that is, are oriented parallel to the rear side  126 ) and terminate as the aforementioned pin terminals  102  at a common plane. 
     Unique to the header assembly  104  according to the present invention, are a plurality of indexing slots: a first indexing slot  128   a , a second indexing slot  128   b , a third indexing slot  128   c , and a fourth indexing slot, each formed at a lower frame portion  130  of the rear side  126  of the header assembly, adjacent the lower left and lower right receptacles  114 ,  118 . The first alignment body  108  has first and second header index spacers  132   a ,  132   b  which seat, respectively, into the first and second indexing slots  128   a ,  128   b  in the manner depicted at FIGS. 7 and 8. The second alignment body  108 ′ has third and fourth header index spacers  132   c ,  132   d  which seat, respectively, into the third and fourth indexing slots  128   c ,  128   d , again in the manner depicted at FIGS. 7 and 8. 
     The first, second, third and fourth header index spacers  132   a ,  132   b ,  132   c ,  132   d  are dimensioned to locate each of the alignment holes  110  exactly in alignment with its respective pin terminal  102 . Further, the minimum spacing between the rear side  126  and the first and second bodies  108 ,  108 ′ is fixed thereby. Further, the seating prevents a lateral force (directed to the left or right of FIG. 9 parallel to the rear side  126 ) from misaligning the terminal pins. Indexing of the first and second alignment bodies  108 ,  108 ′ is provided by the location and relative spacing of the first and second header index spacers  132   a ,  132   b  and their respective first and second indexing slots  128   a ,  128   b  being different from that of the third and fourth header index spacers  123   c ,  132   d  and their respective third and fourth indexing slots  128   c ,  128   d , as best depicted at FIG.  8 . 
     Turning attention now to FIGS. 3 through 6, the configuration of first and second alignment bodies  108 ,  108 ′ will now be detailed, wherein FIGS. 3 and 4 depict the first alignment body  108 , and FIGS. 5 and 6 depict the second alignment body  108 ′. 
     The first alignment body  108  has a top side  134  and an opposite bottom side  136 , wherein the alignment holes  110  pass normally between the top and bottom sides. The first alignment body  108  is elongated and characterized by a forward body member  138 , a rearward body member  140 , and a medial body member  142  integrally formed therewith. The alignment holes  110  formed in the forward body member  138  are arranged in an alignment hole bank  118   h  corresponding to the arrangement of the fourth pin terminal bank  118   p  associated with the lower right receptacle  118  (see FIGS.  7  and  8 ). The alignment holes  110  formed in the rearward body member  140  are arranged in an alignment hole bank  116   h  corresponding to the arrangement of the third pin terminal bank  116   p  associated with the upper right receptacle  116 . 
     The alignment holes  110  at the top side  136  are each provided with a guide cone  144  having increasing cross-section with increasing proximity to the top side. It is preferred for the maximum cross-section of each guide cone  144  (at the top side  134 ) to be approximately three times the cross-section of the alignment holes  110  (at the bottom side  136 ), wherein the depth of each cone  144  is approximately equal to the thickness of the forward body member  138 , wherein it is preferred for the rearward body member  140  to be approximately twice as thick as the forward body member. The guide cones  144  serve to guidably engage each pin terminal  102  into its respective alignment hole  110 , particularly at initial entry. 
     The bottom side  136  is preferably flat, and is provided with a pair mutually spaced apart stand-offs  146 . The stand-offs  146 , as can be understood from FIG. 7, extend as studs perpendicularly from the bottom side  136  a distance that is predetermined to be less than the length of protrusion of the pin terminals  102  at the bottom side. The stand-offs  146  serve to abut the PCB  106  (per FIG. 9) so as to separate the first alignment body  108  from the PCB sufficiently so that moisture will not be trapped therebetween, and further to ensure that the first alignment body will not abut solder connections of the PCB. 
     The forward edge  148  of the first alignment body  108  is provided with the aforementioned first and second header index spacers  132   a ,  132   b , and the rearward edge  150  is generally flat. 
     The left end of the bottom side  136  of the first alignment body  108  is provided with a normally projecting PCB index leg  152  which extends longer than the stand-offs  146  and seats into a predetermined index seat  106   b  (such as for example an index hole) formed in the PCB  106  to thereby index the PCB with respect to the first alignment body  108  and thereby ensure that the correct PCB is aligned with the pin terminals  102 . 
     The second alignment body  108 ′ has a top side  134 ′ and an opposite bottom side  136 ′, wherein the alignment holes  110  pass normally between the top and bottom sides. The second alignment body  108 ′ is elongated and characterized by a forward body member  138 ′, a rearward body member  140 ′, and a medial body member  142 ′ integrally formed therewith. The alignment holes  110  formed in the forward body member  138 ′ are arranged in an alignment hole bank  114   h  corresponding to the arrangement of the second pin terminal bank  114   p  associated with the lower left receptacle  114  (see FIG.  8 ). The alignment holes  110  formed in the rearward body member  140 ′ are arranged in an alignment hole bank  112   h  corresponding to the arrangement of the first pin terminal bank  112   p  associated with the upper left receptacle  112 . 
     Geometrically identical with the first alignment body  108 , the alignment holes  110  at the top side  134 ′ are each provided with a guide cone  144  having increasing cross-section with increasing proximity to the top side. Again, it is preferred for the rearward body member  140 ′ to be approximately twice as thick as the forward body member  138 ′. The guide cones  144  of the second alignment body  108 ′ again serve to guidably engage each pin terminal  102  into its respective alignment hole  110 , particularly at initial entry. The bottom side  136 ′ of the second alignment body  108 ′ is preferably flat, and is provided with a pair mutually spaced apart stand-offs  146 , identical structurally and operatively as recounted with respect to the first alignment body  108 . 
     The forward edge  148 ′ of the second alignment body  108 ′ is provided with the aforementioned third and fourth header index spacers  132   c ,  132   d , and the rearward edge  150 ′ is, again, generally flat. 
     In operation, the first or the second alignment body  108 ,  108 ′ is brought up to its respective banks of pin terminals, wherein the guide cones  144  face the pin terminals  102 . The selected alignment body is then moved relative to the header assembly  104  so that the pin terminals enter into the cones, one pin terminal per alignment hole. The alignment body is then slid up the pin terminals until the header index spacers seat on their respective indexing slots. The other of the first and second alignment bodies is then placed onto its respective banks of pin terminals in the manner aforesaid, wherein these processes may be performed mechanically or manually. Lastly, a preselected PCB  106  is brought up to the banks of pin terminals, and, with the PCB index leg engaged into its index seat  106   b  on the PCB (thereby assuring correct parts assembly) the pin terminals are inserted into respective pin receiving holes  106   a  of the PCB and then soldered in place (see FIG.  9 ). 
     It is to be understood that the terminal pin alignment system according to the present invention is described here merely be way of preferred example, and is usable with any header assembly and any PCB, within the scope defined by the appended claims. 
     To those skilled in the art to which this invention appertains, the above described preferred embodiments may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.