Abstract:
An electrical connector module assembly is disclosed having a connector header usable with multiple module bodies. At least one module body has integral alignment members for aligning printed circuit contact portions with the module body and with a connected substrate.

Description:
BACKGROUND 
       [0001]    The present embodiment relates to an electrical connector module assembly, and more particularly to a module assembly having a connector header which can have alternative uses. 
         [0002]    It is quite common in the automotive industry to provide electronic control modules. Such modules are useful for controlling any of the engine functions, such as air fuel ratio, ignition, fuel injection, and the like. Typically, the modules include a module body or casing having a substrate positioned therein, where the substrate includes electronic components to control the various functions. The substrate could comprise a printed circuit board or flexible substrate. The substrate would include a connection mechanism adjacent to an edge thereof, where the connector is positioned adjacent an opening of the casing. The casing would thereafter be positionable adjacent to the engine, where the connector on the control module would complement a connector on the engine device to be monitored/controlled. The modules could be sealed or unsealed. 
         [0003]    In some applications, it would be desirable to provide a connector assembly wherein a separable and discrete connector header is provided which may alternatively be used with a first or second module body. 
       SUMMARY 
       [0004]    In one embodiment, an electrical connector module assembly comprises a connector header having an insulative housing and a plurality of electrical terminals mounted therein. The electrical terminals having mating contact portions and printed circuit contact portions extending outwardly from the insulative housing. A module body defines an enclosure and has a module mating face and a connector header receiving area defined adjacent the module mating face. The header receiving area defines a receiving opening to receive the connector header and an alignment area to align the printed circuit contact portions. 
         [0005]    In another embodiment described herein a method of manufacturing an electrical connector module assembly is described, comprising the steps of providing a connector header having an insulative housing and a plurality of electrical terminals mounted therein. The electrical terminals have mating contact portions and printed circuit contact portions extending outwardly from the insulative housing. A first module body is provided defining an enclosure and having a module mating face, and a connector header receiving area defined adjacent the module mating face. The header receiving area defines a receiving opening to receive the connector header and an alignment area to align the printed circuit contact portions. A second module body is provided which defines an enclosure. A printed circuit board is provided and the first or second module body is selected. The connector header is inserted into the selected module and the printed circuit contact portions are connected with associated contact members on the board. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0006]      FIG. 1  is a top perspective view of a first embodiment of an electrical connector module assembly; 
           [0007]      FIG. 2  is a bottom perspective view of the electric connector module assembly of  FIG. 1 ; 
           [0008]      FIG. 3 , is an exploded view of the electrical connector module assembly of  FIG. 1 ; 
           [0009]      FIG. 4  is a top perspective view of the connector header of the electrical connector module assembly; 
           [0010]      FIG. 5  is a bottom perspective view of the connector header of the electrical connector module assembly; 
           [0011]      FIG. 6  is a side view of the connector header of the electrical connector module assembly; 
           [0012]      FIG. 7  is a rear perspective view of the connector header of the electrical connector module assembly; 
           [0013]      FIG. 8  is an enlarged view of the section denoted in  FIG. 7 ; 
           [0014]      FIG. 9  is a top plan view of the inside of the module body of the electrical connector module assembly; 
           [0015]      FIG. 10  is a bottom perspective view of the inside of the module body of the electrical connector module assembly; 
           [0016]      FIG. 11  is an enlarged view of the section denoted in  FIG. 10 ; 
           [0017]      FIG. 12  is a bottom perspective view of the assembled module body and connector header; 
           [0018]      FIG. 13  is an enlarged view of the section denoted in  FIG. 12 ; and 
           [0019]      FIG. 14  is an alternate embodiment using the connector header of  FIGS. 4-8  with an alternate module body. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0020]    With reference first to  FIGS. 1-3 , an electrical connector module assembly is disclosed at  2 , having a connector header  4 , a module body  6 , a substrate  8 , shown here as a printed circuit board, and a cover  10 . As shown, connector header  4  is comprised of an insulative housing  12  having a plurality of electrical terminals  14  mounted therein. The electrical terminals  14  comprise mating contact portions  16  and printed circuit contact portions  18 . Substrate  8  also comprises contact areas  20  on substrate  8  which correspond in number and orientation with, printed circuit contact portion  18 . 
         [0021]    With reference now to  FIGS. 4-8 , connector header  4  will be described in greater detail. Connector header  4  has sidewalls  22 ,  24 , end walls  26 ,  28  and rear wall  30 , all of which define one or more cavities  36 ,  38 . Electrical terminals extend through rear wall  30  such that mating contact portions  16  project into one or more cavities  36 ,  38  while printed circuit contact portions  18  extend rearwardly from rear wall  30 . As shown, connector header  4  has plural rows of mating contact portions  16  and plural rows of printed circuit contact portions  18 . As shown best in  FIG. 6 , the printed circuit contact portions  18  extend at a substantial right angle relative to the mating contact portions  16 , with each row of mating contact portions having their corresponding printed circuit contact portions  18  extend over the previous row. A lip  40  extends substantially around top wall  22  and sidewalls  26 ,  28  and will define a portion of an alignment assembly as further defined herein. With reference now to  FIGS. 7 and 8 , printed circuit contact portions  18  are shown in greater detail. Each of the printed circuit contact portions  18  comprises a blade or tine portion  50 , a cross bar  52  and a compliant pin portion  54 . 
         [0022]    With reference now to  FIGS. 9-11 , module body  6  will be described in greater detail. Module body  6  comprises a top wall  60 , end wall  62 , sidewalls  64 ,  66  and with reference again to  FIG. 3 , a shroud  70 . With reference to both  FIGS. 3 and 9 , module body  6  has alignment bars  72 ,  74  which define a slot  80 . Alignment bars  72 ,  74  and lip  40  combine to define alignment assembly as more fully described herein. With reference still to  FIG. 3 , module  6  further includes a wall  90 . As shown in  FIG. 3 , wall  90 , sidewalls  64 ,  66 , end wall  62  and top wall  60  combine to define an enclosure  92 , whereas wall  90  extends laterally between sidewalls  64 ,  66  and spans the enclosure  92 . Furthermore, wall  90 , together with shroud  70  combine to define a connector header receiving area  94 . 
         [0023]    With reference now to  FIGS. 10 and 11 , wall  90  is shown as divided into a plurality of Columns  100  thereby defining intermediate spacings  102 . It should be appreciated that the wall  90  could be separated laterally into a plurality of rows. However, given the configuration of connector header  4 , and particularly the printed circuit contact portions  18 , wall  90  defines individual columns  100 . As shown, each of the spacings  102  have alignment members  110  flanking the spacing  102 . The alignment members are defined by pairs of notches where each notch is defined by a top surface  120 , side surfaces  122 ,  124 , and end surfaces  126 . Thus the alignment members  110  provide alignment in three dimensions; that is, in the x-direction by end surfaces  126 , in the y-direction by top surface  120 , and in the z-direction by side surfaces  122 ,  124 . 
         [0024]    With reference again to  FIG. 3 , connector header  4  is shown exploded away from module body  6 . Connector header  4  may be assembled to module body  6 , by moving connector header  4  upwardly (as viewed in  FIG. 3 ) such that lip  40  is positioned behind alignment bars  72 ,  74 , (and into slot  80 ,  FIG. 9 ) and with the individual printed circuit contact portions  18  aligned with the spacings  102 . Thus, the same movement of the connector header  4  into alignment with the module body  6 , also moves the printed circuit contact portions  18  into the spacings  102 , and the cross bars  52  into corresponding alignment members  110 .  FIGS. 12 and 13  show the connector header  4  in the fully inserted position in the module body  6  with cross bars  52  in the fully inserted position within alignment members  110 . 
         [0025]    To complete the assembly of electrical connector module assembly  2 , and with reference still to  FIG. 3 , substrate  8  would be positioned within module body  6 , with contact areas  20  in connection with compliant pin portions  54 . As shown, contact areas  20  are through holes, but any type of connection such as surface mount or other connection could be used. Cover  10  would now be positioned in place against module body  6 , and over substrate  8 , and fasteners (not shown) would be positioned through apertures  130  and  132 , and into connection with bosses  134 . 
         [0026]    Alternatively, and with reference to  FIG. 14 , an alternate electrical connector module assembly  202  could be assembled using the same connector header  4 , however with an alternate module body  206  and substrate  208 . It should be appreciated that module body  206  is shown somewhat diagrammatically, and it should be understood that any configuration could be used for the module body  206 . 
         [0027]    While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. The application is, therefore, intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.