ELECTRICAL ASSEMBLY

An assembly includes a module including a housing having a first portion, a second portion including a projection, and a first interior cavity; and a circuit board disposed at least partially in the first interior cavity; and an additional module connected under tension with the module, the additional module including: an additional housing having a recess and an additional interior cavity; and an additional circuit board disposed at least partially in the additional interior cavity. The second portion of the housing may be disposed at least partially in the additional interior cavity. The projection of the housing may be disposed at least partially in the recess of the additional housing. The circuit board may be electrically connected to the additional circuit board.

TECHNICAL FIELD

The present disclosure generally relates to electrical assemblies, including modules that may, for example, be utilized in connection with and/or incorporated into vehicles.

DETAILED DESCRIPTION

FIGS.1and2present an electrical assembly20including a first module30, a second module40, and/or a plurality of third modules50(e.g., third modules50A-50I). The first module30is configured for connection with a third module50. The second module40is configured for connection with a third module50. A third module50is configured for connection with the first module30, the second module40, and/or one or more additional third modules50. The first module30, the second module40, and/or the third module(s)50may be electrically connected. In some example configurations, the third module(s)50are disposed at least partially between the first module30and the second module40. For example, the third module(s)50may be intermediate or additional modules, the first module30may be a first end module, and the second module40may be a second end module. Some or all of modules30,40,50(e.g., at least adjacent modules) are connected under tension. For example and without limitation, the first module30may be connected under tension with a third module50(e.g., third module50A), the second module40may be connected under tension with the third module50and/or an additional third module50(e.g., third module50I), and/or the third module50may be connected under tension with the first module30, the second module40, and/or an additional third module50(e.g., third module50B).

With some embodiments, the assembly20may be used in connection with one or more bladders of a vehicle seat22of a vehicle24. For instance, a module (e.g., modules30,40,50) may include a bladder control module for a vehicle seat22. A vehicle seat22may include the electrical assembly20and one or more fluid bladders26(e.g., fluid bladders/groups26A-26I) in fluid communication with the electrical assembly20. One or more of the modules30,50may be configured to control fluid flow to and/or from a respective bladder26or group of bladders26, such as to and/or from a fluid source28(e.g., a pump, tank, etc.). For example, one or more modules30,50may include a fluid valve68,108that may be controlled via electronics of the module30,50, such as via a circuit board62,102, a solenoid, expanding/contracting wires, and/or other electronics. The valves68,108of adjacent modules30,50are in fluid communication. For example, connecting adjacent modules30,50may include connecting valves68,108for fluid communication. The first module30may include an inlet port76that may be connected to the fluid source28. The inlet port76may be in fluid communication with the fluid valve68.

Examples of an electrical assembly20are shown including nine third modules50, however the assembly20may include more or less than nine third modules50(e.g., an electrical assembly20may have a modular configuration). For example, some configurations may include one third module50and other configurations may include, two, three, four, five, or other numbers of third modules50. The number of third modules50may correspond to the number of components (e.g., bladders, fluid actuators, etc.) to be controlled.

FIGS.3A,3B, and4illustrate a first module30including a housing60and a circuit board62. The housing60includes an interior cavity64and the circuit board62is disposed at least partially in the interior cavity64. The housing60includes one or a plurality of projections70(e.g., projections70A-70D) and/or one or a plurality of ramped portions72(e.g., ramped portions72A-72F). A first projection70A and a second projection70B may extend from a first side wall66A of the housing60(e.g., an upper wall) and/or a third projection70C and a fourth projection70D may extend from a second sidewall66B of the housing60(e.g., a lower wall). A projection70may include a ramped configuration. The housing60is shown including four projections70, however the housing60may include more or less than four projections70. In some implementations, one or more ramped portions (e.g., ramped portions72A-72C) extend from the first sidewall66A of the housing60, and/or one or more ramped portions (e.g., ramped portions72D-72F) extend from the second sidewall66B of the housing60. A ramped portion72is configured to provide an interference fit with an adjacent module (e.g., a third module50). The housing60is shown including six ramped portions72, however the housing60may include more or less than six ramped portions72. The housing60may comprise one or more materials that are configured to deform (e.g., stretch, bend, flex, etc.), at least to some degree, during assembly, such as one or more plastics and/or polymers. In some examples, the circuit board62includes an electrical connector74that connects to an electrical connector of an adjacent module (e.g., an adjacent third module50).

FIGS.5and6illustrate a second module40including a housing80having an interior cavity84. In some configurations, the housing80includes a plurality of recesses90(e.g., recesses90A-90D). A first recess90A and a second recess90B may be disposed in a first sidewall86A of the housing80(e.g., an upper wall) and/or a third recess90C and a fourth recess90D may be disposed in a second sidewall86B of the housing80(e.g., a lower wall). The housing80is shown including four recesses90, however the housing80may include more or less than four recesses90. The housing80may comprise one or more materials that are configured to deform (e.g., stretch, bend, flex, etc.), at least to some degree, during assembly, such as one or more plastics and/or polymers. Optionally, the second module40includes a circuit board at least partially disposed in the interior cavity84. The circuit board may include an electrical connector that connects to an electrical connector of an adjacent module. In other configurations, the second module40does not include a circuit board or other components and functions as a cover for an adjacent third module50.

FIGS.7and8illustrate a third module50including a housing100and a circuit board102. The housing100includes an interior cavity104and the circuit board102is disposed at least partially in the interior cavity104. The housing100includes a first portion110and a second portion112offset from the first portion110in an assembly direction (e.g., an X-direction). The first portion110may be larger than the second portion112. In some configurations, the first portion110includes a plurality of recesses120(e.g., recesses120A-120D). A first recess120A and a second recess120B may be disposed in a first sidewall122A of the first portion110(e.g., an upper wall) and/or a third recess120C and a fourth recess120D may be disposed in a second sidewall122B of the first portion110(e.g., a lower wall). The housing100is shown including four recesses120, however the housing100may include more or less than four recesses120. The number of recesses120may correspond to the number of projections70of the first module30.

In some implementations, the second portion112of the housing100includes a plurality of projections130(e.g., projections130A-130D). A first projection130A and a second projection130B may extend from a first sidewall132A of the second portion112(e.g., an upper wall) and/or a third projection130C and a fourth projection130D may extend from a second sidewall132B of the second portion112(e.g., a lower wall). A projection130may include a ramped configuration. The housing100is shown including four projections130, however the housing100may include more or less than four projections130. The housing100may comprise one or more materials that are configured to deform (e.g., stretch, bend, flex, etc.), at least to some degree, during assembly, such as one or more plastics and/or polymers. In some examples, the circuit board102includes at least one electrical connector134,136. An electrical connector134,136connects to an electrical connector of an adjacent module. For example, an electrical connector136A of a third module50A may connect with an electrical connector134B of an adjacent third module50B. Additionally or alternatively, an electrical connector134A may connect with an electrical connector74of the first module30. In some configurations, the electrical connectors134,136may provide power and/or data/instructions from the first module30to the one or more third modules50.

With reference toFIG.9, a first module30and two third modules50A-B are shown. In some configurations, a housing100of a third module50includes a first sidewall132A and/or a second sidewall132B that are tapered, such as to provide an interference fit with an adjacent module. For example, a Z-dimension of the second portion112of the housing100may increase in the X-direction, such as toward the first module30. In some implementations, the first sidewall132A and/or the second sidewall132B may include tapered edges to facilitate insertion of an adjacent module30,50.

Referring now toFIG.10, a first sidewall122A and/or a second sidewall122B of a housing100includes a recessed portion140(e.g., recessed portion140A,140B) such that a gap/clearance is disposed between sections of adjacent modules. For example and without limitation, a third module50A may be connected with an additional third module50B such that a recessed portion140A is disposed between a first sidewall122A of the third module50A and a first sidewall122A′ of the additional third module50B. Additionally or alternatively, a recessed portion140B is disposed between a second sidewall122B of the third module50A and a second sidewall122B′ of the additional third module50B. The recessed portions140A-B may result in reduced contact in the X-direction between adjacent sidewalls122A,122A′ and122B,122B′. For example, the recessed portions140may extend along at least 70% of the sidewalls122A,122A′ and contact in the X-direction between sidewalls122A,122A′ may be along 30% or less of their Y-dimension lengths. A depth of the recessed portions140in the X-direction may correspond to an offset170between adjacent modules described below. For example, the depth of the recessed portions140may be at least as great as the offset170, which may facilitate connecting adjacent modules (e.g., third modules50A,50B), such as by providing room for stretching of the sidewalls.

With reference toFIGS.7and12, a housing (e.g., housings60,80,100) may include at least one track150and/or at least one channel160. For example and without limitation, a second portion112portion of a housing100may include at least one track150and a first portion110of the housing100may include at least one channel160. In some implementations, a third sidewall132C of the second portion112may include a first track150A and a fourth sidewall132D of the second portion112may include a second track150B. A third sidewall122C of the first portion110may include a first channel160A and a fourth sidewall122D of the first portion110may include a second channel160B. A track150may include a dovetail-shaped configuration. A channel160may include a shape that corresponds to a shape of a track150. In an assembled configuration, a module (e.g., third module50A) may be connected with an adjacent module (e.g., third module50B) such that a track150of the module is disposed in and/or engaged with a channel160of the adjacent module (see, e.g.,FIG.12). Engagement between a track150of a module and channel160of an adjacent module may restrict and/or prevent relative movement between the two modules in the Y-direction and the Z-direction, and may not substantially restrict movement in the X-direction.

With reference toFIGS.1,2,9, and10, in an assembled configuration, adjacent modules are connected under tension. For example and without limitation, the first module30may be connected under tension with a third module50(e.g., third module50A), the second module40may be connected under tension with the third module50A and/or an additional third module50(e.g., third module50I), and/or the third module50may be connected under tension with the first module30, the second module40, and/or an additional third module50(e.g., third module50B).

In some implementations, the first module30is connected with a third module50A such that a portion of the first module30is disposed at least partially in an interior cavity104A of the third module50A, a projection70of the first module30is disposed at least partially within a recess120of the third module50A, and/or a circuit board62of the first module30is electrically connected with a circuit board102A of the third module50A via electrical connectors74,134.

In some instances, the third module50A may be connected with an additional third module50B such that a second portion112A of a housing100A of the third module50A is at least partially disposed in an interior cavity104B of the additional third module50B. A projection130of the third module50A is at least partially disposed within a recess120′ of the additional third module50B. The electrical connector134B of the third module50B is connected (e.g., directly) to the electrical connector134A of the third module50such that the circuit board102A of the third module50A is electrically connected with a circuit board102B of the additional third module50B (see, e.g.,FIG.13).

Referring now toFIG.11, the third module50A may be connected under tension with the additional third module50B at least in part because of a pre-assembly/flex offset170between a projection130of the third module50A and a surface180defining a recess120′ of the additional third module50B. The offset170may be the X-direction distance between the projection(s)70,130of one module30,50and the recess(es)90,120of the adjacent module40,50when the one module is fully inserted into the adjacent module. For example, when one module30,50is fully inserted into the adjacent module40,50, the projection(s)70,130may not be aligned with the recess(es)90,120. The housing80,100of the adjacent module40,50may then be stretched at least the distance of the offset such that projection(s) and the recess(es)90,120are aligned for engagement. The pre-assembly/flex offset may, for example and without limitation, be approximately 0.2 mm to 0.3 mm.

In some examples, the second module40may be connected with a third module50such that a second portion112of a housing100of the third module50is at least partially disposed within an interior cavity84of the second module40. A projection130of the third module50is at least partially disposed within a recess90of the second module40. If the second module40includes a circuit board, the circuit board may be electrically connected with a circuit board102of the third module50.

Adjacent modules30,50are connected under tension such that electrical connectors74,134of the adjacent modules30,50are connected under tension which restricts movement between the electrical connectors74,134, so that the adjacent modules30,50do not become unintentionally disconnected and wear/fretting of the electrical connectors74,134is limited. For example and without limitation, as shown inFIG.13, a third module50A may be connected with an additional third module50B such that an electrical connector134A of the third module50A is connected under tension with an additional electrical connector134B of the additional module50B and/or a circuit board102A of the third module50A is electrically connected with an additional circuit board102B of the additional third module50B.

In one example assembled configuration, a first module30(e.g., a first end module) is disposed partially in a third module50A (e.g., a first additional module), the third module50A is disposed partially in another third module50B (e.g., a second additional module), and/or the another third module50B is partially disposed in yet another third module50C (e.g., a third additional module) or the second module40(e.g., a second end module).

A method of assembling an electrical assembly20includes connecting at least two modules30,40,50together. In configurations with one third/intermediate module50, the third module50is connected with a first module30(e.g., a first end module) and a second module40(e.g., a second end module). Connecting the third module50with the first module30includes inserting a portion of the first end module30into the first portion of the housing100of the third module. Insertion may continue until the housing100contacts the projections70and/or the ramped portions72of the housing60of the first end module30. An offset170between the projections70of the housing60and the recesses120of the housing100may result in the projections70not initially engaging the recesses120. The housing100may then be stretched in the X-direction (e.g., to compensate for the offset170) such that the recesses120extend at least to the end of the projections70and the projections70can be inserted into/engaged with the recesses120. Once the projections70are inserted into/engaged with the recesses120, the housing100may be released from being stretched and may move/retract toward its original position (e.g., due to a resiliency of the material(s) of the housing100), but may not move/retract completely its original position, which may result in the housings60,100being connected under tension of the still partially stretched housing100. This tension biases the housings60,100toward each other and limits and/or substantially prevents relative movement therebetween. During insertion and/or stretching of the housing100in the X-direction, the housing100may also be stretched and/or deformed in the Z-direction. For example, the outer dimensions of the housing60(e.g., proximate the projections70and/or ramped portions72) may be similar to or even at least slightly larger than the inner dimensions of the first portion110of the housing100(e.g., in the Z-direction) such that the first portion110deflects outward at least to some degree, which may cause the first portion110to apply a Z-direction force to the housing60(e.g., resulting from the resiliency of material(s) of the housing100). This deflection and force may result in the housings60,100be connected under tension in two directions, the X-direction and the Z-direction. The ramped portions72may enhance/promote deflection of the first portion110in the Z-direction, which may increase the tension between adjacent modules.

In configurations with a single third/intermediate module50, the second module40is connected to the opposite side of the third module50from the first module. The connection process may be similar to the connection of the third module50with the first module30. For example, the second portion112of the third module50may be inserted into the interior cavity84of the second module40and the housing80may be stretched in the X-direction and/or the Z-direction to allow the projections130of the third module50to be inserted into the recesses90of the second module40. The housing80may be released from stretching forces, but may not fully return to its original position/shape such that the housings80,100are connected under tension. For example, a sidewall122A may be stretched from an original position to a stretched position, and, once released, may move back toward its original position to an engaged position between the original position and the stretched position.

FIG.14illustrates a method of connecting two third/intermediate modules50of an electrical assembly20that includes a plurality of third/intermediate modules50. The third modules50may be connected to each other in a similar manner as the first module30and the adjacent third module50described above. A third module (e.g., third module50C) may be connected to an adjacent module (e.g., third module50B) such that the module is connected under tension to the adjacent module. Connecting the adjacent modules may include moving one module in an assembly direction200(e.g., parallel to the X-axis) such that a portion of the adjacent module (e.g., second portion112B) is disposed in an interior cavity (e.g., interior cavity104C) of the module. Connecting two modules may include manipulating (e.g., stretching) a housing of the module (e.g., housing100C) in a vertical direction (e.g., parallel to the Z-axis) and a horizontal direction (e.g., parallel to the X-axis) such that a projection (e.g., projections130A′-130D′) of the adjacent module is disposed within a recess (e.g., recesses120A″-120D″) of the housing of the module and the module is connected under the tension to the adjacent module. In some instances, one or more additional recesses (e.g.,140A″ and140B″) of the housing helps facilitate the manipulation of the housing over the additional housing (e.g., housing100B) of the adjacent module. In some examples, prior to the manipulation, the housing is in a first position, during the manipulation the second housing deforms (e.g., is “stretched”) to a second position, and when released from the deformation, the second housing moves to a third position which is different than the first position.

In at least some assembled configurations, each of the modules30,40,50may be at least indirectly connected under tension with each other module30,40,50of an electrical assembly. For example and without limitation, the first module30may be indirectly connected under tension with the second module40via one more third/intermediate modules50.

In some implementations, the third module50A is connected with the additional third module50B such that a gap190in the Z-direction is disposed between the first and second sidewalls132A′,132B′ of the housing100B of the additional third module50B and ends of the first and second sidewalls132A,132B of the housing100A of the third module50A (see, e.g.,FIG.9). The gap190may, for example and without limitation, be triangular.

While examples are described with inserted portions of modules30,50including projections70,130received by recesses90,120of a receiving portion of a module40,50, such a configuration may be reversed and/or mixed such that inserted portions of modules include recesses or recesses and projections.

This disclosure includes, without limitation, the following embodiments:

1. An assembly, comprising: a module including: a housing having a first portion, a second portion including a projection, and a first interior cavity; and a circuit board disposed at least partially in the first interior cavity; and an additional module connected under tension with the module, the additional module including: an additional housing having a recess and an additional interior cavity; and an additional circuit board disposed at least partially in the additional interior cavity; wherein the second portion of the housing is disposed at least partially in the additional interior cavity; the projection of the housing is disposed at least partially in the recess of the additional housing; and the circuit board is electrically connected to the additional circuit board.

2. The assembly according to embodiment 1, wherein the projection extends from a first side of the housing; the housing includes a second projection that extends from a second side of the housing; and the projection and the second projection include a ramped configuration.

3. The assembly according to any preceding embodiment, wherein the housing includes a ramped portion to provide an interference fit with the additional housing.

4. The assembly according to any preceding embodiment, wherein the projection is disposed on the ramped portion.

5. The assembly according to any preceding embodiment, wherein the additional housing includes an additional housing first portion having the recess and an additional housing second portion having an additional housing projection.

6. The assembly according to any preceding embodiment, wherein the additional housing includes a first sidewall and a second sidewall; and the first sidewall and the second sidewall of the additional housing include tapered edges.

7. The assembly according to any preceding embodiment, wherein the first sidewall and the second sidewall of the additional module include an additional recess such that in an assembled configuration a gap/clearance is disposed between sections of adjacent modules.

8. The assembly according to any preceding embodiment, wherein the housing of the module includes a track; and the first portion of the additional housing includes a channel engaged with track such that relative movement of the module and the additional module is restricted in a lateral direction and a vertical direction.

9. The assembly according to any preceding embodiment, wherein the module is a first end module; the assembly further comprises a second end module; the additional module is disposed at least partially between the first end module and the second end module; the second end module includes a second end module housing having a second end module recess and a second end module interior cavity; and the second end module is connected, at least indirectly, with the additional module.

10. The assembly according to any preceding embodiment, wherein the first end module and the second end module are connected, at least indirectly, under tension with the additional module.

11. The assembly according to any preceding embodiment, wherein the additional housing includes an additional housing first portion having the recess and an additional housing second portion having an additional housing projection; and the second portion of the additional housing is at least partially disposed in the second end module interior cavity.

12. The assembly according to any preceding embodiment, including a second additional module connected under tension with one or both of the additional module and the second end module.

13. The assembly according to any preceding embodiment, wherein the second additional module and the additional module are connected under tension via a pre-assembly offset between the projection of the additional module and a second additional module recess of the second additional module.

14. The assembly according to any preceding embodiment, wherein the first end module, the additional module, and the second additional module are electrically connected.

15. The assembly according to any preceding embodiment, wherein the first end module, the additional module, and the second additional module include respective fluid valves that are in fluid communication with each other.

16. The assembly according to any preceding embodiment wherein walls of the additional module and the second additional module include recessed portions that facilitate stretching.

17. The assembly according to any preceding embodiment, wherein the additional module includes an additional module projection; the second additional module includes a second additional module recess; and a depth of the recessed portions corresponds to an offset of the additional module projection and the second additional module recess.

18. The assembly according to any preceding embodiment, wherein the second additional module includes a second additional module housing; the second additional module housing includes a first sidewall and a second sidewall; and the first sidewall and the second sidewall of the second additional module housing include tapered edges.

19. The assembly according to any preceding embodiment, wherein the first end module is disposed partially in the additional module; the additional module is disposed partially in the second additional module; and the second additional module is partially disposed in a third additional module or the second end module.

20. A vehicle seat, comprising the assembly according to any preceding embodiment; and one or more fluid bladders in fluid communication with the assembly.

Various examples/embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples/embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the examples/embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the examples/embodiments described in the specification. Those of ordinary skill in the art will understand that the examples/embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to “examples, “in examples,” “with examples,” “various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the example/embodiment is included in at least one embodiment. Thus, appearances of the phrases “examples, “in examples,” “with examples,” “in various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more examples/embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the various described embodiments. The first element and the second element are both element, but they are not the same element.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements, relative movement between elements, direct connections, indirect connections, fixed connections, movable connections, operative connections, indirect contact, and/or direct contact. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. Connections of electrical components, if any, may include mechanical connections, electrical connections, wired connections, and/or wireless connections, among others. Uses of “e.g.” and “such as” in the specification are to be construed broadly and are used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples.