Abstract:
A lead frame assembly having a lead frame made of a single layer, a housing substantially surrounding the lead frame, and a plurality of leads formed as part of the lead frame. The lead frame assembly also includes a plurality of interfaces, allowing various devices to interact with the lead frame, such as sensors, thermistors, solenoids, engine controllers, or electronic control units, or the like. The interfaces may be formed as part of the lead frame, oriented in different directions, and may be located in different planes, making the lead frame assembly suitable for applications with different packaging requirements. The interfaces may be a plurality of connectors, where one of the connectors has multiple rows of pins which are in communication with the rest of the connectors, facilitating the communication between the connector and various devices.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part application, which claims the benefit of U.S. application Ser. No. 13/768,415 filed Feb. 15, 2013. The disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates generally to multiple sub-lead frames being associated with a connector having multiple rows of pins, and each sub-lead frame has at least one pin that is in electrical communication with one or more of the rows of pins that are part of the connector. 
       BACKGROUND OF THE INVENTION 
       [0003]    Lead frames are commonly used to provide electrical communication between various electrical components. The lead frame typically includes metal leads which extend outside of a housing for providing a connection between various components. 
         [0004]    Lead frames also may include a connector, which is mounted to the housing, for providing electronic communication between the lead frame and other devices. There are also applications where is it necessary to have multiple connectors either formed as part of the lead frame, or attached to the lead frame. One type of a design incorporates the use of a lead frame having multiple layers, to provide for the use of multiple connectors. Still other applications require the use of a single connector which is in electrical communication with multiple connectors that are part of the lead frame having multiple layers. These multiple layer lead frames are typically constructed using a housing surrounding the multiple layers, with the multiple layers being separated by a portion of the housing. One of the issues that may occur during manufacturing of these types of lead frames is electrical shorts occurring as a result from mechanical slivers from plating or from the mold inserts closing on the stamping and dislodging the slivers from the edge of the stamping. Additionally, lead frames having multiple layers are more expensive to manufacture because of the multiple pre-molds required for the additional layers. 
         [0005]    Accordingly, there exists a need for a lead frame which allows for the use of multiple connectors, as well as multiple lead frames having a layered structure, while remaining cost feasible to manufacture. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention is a lead frame assembly having several sub-lead frames, each of which is in electrical communication with a single connector, providing electrical communication with several components using the single connector. The lead frame assembly includes a first sub-lead frame and a second sub-lead frame, where at least part of each of the first and second sub-lead frames is in a first plane, and a third sub-lead frame, which is partially disposed in a second plane. A housing substantially surrounds a portion of each of the sub-lead frames, and an upper connector is integrally formed as part of the housing. 
         [0007]    A plurality of leads are formed as part of the first sub-lead frame and the second sub-lead frame, and in one embodiment, each of the plurality of leads is connected to a solenoid. 
         [0008]    The lead frame assembly also includes a plurality of sub-connectors, where a portion of the plurality of sub-connectors are part of the first sub-lead frame, a portion of the plurality of sub-connectors are part of the second sub-lead frame, and a portion of the plurality of sub-connectors are part of the third sub-lead frame. 
         [0009]    Each of the sub-connectors in is electrical communication with an upper connector having multiple rows of pins. The upper connector extends from the first plane outwardly away from the first sub-lead frame and the second sub-lead frame. The upper connector includes a first row of pins, a second row of pins, and a third row of pins located between the first row of pins and the second row of pins. At least a portion of the first and second rows of pins is part of each of the first sub-lead frame and the second sub-lead frame, and at least a portion of the third row of pins is part of the third sub-lead frame. Additionally, a portion of the second row of pins is in electrical communication with one or more of the plurality of leads. 
         [0010]    The plurality of sub-connectors also includes varying amounts of pins in electrical communication with one or more of the rows of pins of the upper connector, and the pins are exposed outside of the housing for connection with electronic devices. 
         [0011]    The first sub-lead frame includes three sub-connectors located in the first plane and in electrical communication with at least a portion of the first row of pins, the second sub-lead frame includes a sub-connector located in the first plane and in electrical communication with at least a portion of the first row of pins, and the third sub-lead frame includes two sub-connectors located in the second plane, and in electrical communication with at least a portion of the third row of pins. 
         [0012]    It is an object of this invention to provide a lead frame assembly which may be used with several different devices, such as, but not limited to sensors, thermistors, solenoids, engine controllers, or electronic control units, or any other device suitable for connection with a lead frame using one or more interfaces or connectors. In one embodiment, the interfaces are located in different planes, allowing for the connection to the lead frame to be in different planes. 
         [0013]    It is another object of this invention to provide a lead frame having a single layer to incorporate a three-row connector system. In one embodiment, the additional third row is added to the center of a dual row connector. This third center row is part of a separate sub-lead frame incorporated into the lead frame assembly, and assembled on the bottom side of the lead frame assembly. 
         [0014]    It is another object of this invention to provide a three-row connector incorporated into a single layer lead frame. This provides a cost effective solution for two-row connectors and potential expansion to three-row connectors at minimal costs. The lead frame assembly of the present invention also expands the connector ports and interconnectors on the lead frame. Connectors having a low pin count are used with the basic lead frame, while connectors having a high pin count may add expansion to the lead frame and add the third row. The three-row connector may be used for providing a single interface to communicate with many sub-connectors that are connected to various components. 
         [0015]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0017]      FIG. 1  is a perspective view of a lead frame having multiple connectors, according to embodiments of the present invention; 
           [0018]      FIG. 2  is a top view of a portion of a lead frame having multiple connectors, according to embodiments of the present invention; 
           [0019]      FIG. 3  is a perspective view of a lead frame assembly with the housing and the shroud for each connector removed, according to embodiments of the present invention; 
           [0020]      FIG. 4  is a perspective view of a sub-assembly, which is part of a lead frame assembly, according to embodiments of the present invention; and 
           [0021]      FIG. 5  is a second perspective view of a lead frame having multiple connectors, according to embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0023]    An embodiment of a lead frame assembly according to the present invention is shown in  FIGS. 1-5  generally at  10 . The lead frame assembly  10  includes a frame portion, or lead frame,  12  having a plurality of leads  14 . The lead frame  12  in this embodiment includes several sub-lead frames. There is a first sub-lead frame, shown generally at  12 A, a second sub-lead frame, shown generally at  12 B, and a third sub-lead frame, shown generally at  12 C, with a portion of the leads  14  being part of the first sub-lead frame  12 A and the second sub-lead frame  12 B. The lead frame  12  and leads  14  are at least partially surrounded by a housing  16 . The housing  16  is molded around the lead frame  12  and leads  14 , and is made of a plastic moldable material, such as epoxy, nylon, polyethylene, or polystyrene. 
         [0024]    The sub-lead frames  12 A,B are made of a single layer, shown generally at  18 A, where the single layer  18 A defines a first plane. Integrally formed as part of the housing  16  is more than one interface. Each interface is used for allowing communication as well as a connection with the lead frame  12 . In this embodiment, the plurality of interfaces is a plurality of connectors. However, other types of interfaces may be used to allow the lead frame  12  to be used with different devices, such as, but not limited to, thermistors, solenoids, sensors, or the like. Furthermore, the other devices, such as the sensors, thermistors, solenoids, engine controllers, or electronic control units, may be directly connected to the lead frame  12 , and in other embodiments, the other devices may be integral with the lead frame  12 . 
         [0025]    In the embodiment shown in  FIGS. 1-5 , there is a first connector  20 , a second connector  22 , and a third connector  24 , which are integral with the housing  16 , and the connectors  20 , 22 , 24  and layer  18 A are located in the first plane  18 A. The connectors  20 , 22 , 24  are associated with the first sub-lead frame  18 A. There is also a fourth connector  26  and a fifth connector  28  associated with the third sub-lead frame  12 C, and the housing  16  partially surrounds the fourth connector  26  and the fifth connector  28 . The fourth connector  26  and fifth connector  28  are located in a second plane, shown generally at  18 B, which is substantially parallel to and separate from the first plane  18 A. In this embodiment, the fourth connector  26  and fifth connector  28  are located below the connectors  20 , 22 , 24 . A sixth connector, which in this embodiment is an upper connector  30 , is associated with all three sub-lead frames  12 A,B,C, and is at least partially surrounded by the housing  16 . The sixth connector  30  faces and extends outwardly away from the lead frame  12 , on the opposite side as the fourth sub-connector  26  and fifth sub-connector  28 , as shown in  FIGS. 1 ,  2 , and  5 . There is also a seventh connector  32 , which is shown in  FIG. 2  and associated with the second-lead frame  12 B. The seventh connector  32  is located in the first plane  18 A. 
         [0026]    The connectors  20 , 22 , 24 , 26 , 28 , 32  in this embodiment are all sub-connectors, and are all in electrical communication with the upper connector  30 . Each of the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  also includes one or more pins  34  which are in electrical communication with the lead frame  12 , which therefore provide electrical communication between the components connected to the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  and the lead frame  12 . Some of the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  have a greater number of pins (a high pin count), and other connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  have a lesser number of pins (a low pin count), depending upon the use for the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32 . 
         [0027]    More specifically, the upper connector  30  is a three-row connector  30 , and includes a first row of pins, shown generally at  30 A, a second row of pins, shown generally at  30 B, and a third row of pins, shown generally at  30 C. Referring now to  FIGS. 2-3 , the first row  30 A of pins  34  has fourteen pins, and it is shown that the pins  34  for the first three connectors  20 , 22 , 24  of the first sub-lead frame  12 A are associated with twelve of the pins  34  in the first row  34 A of pins  34  of the upper connector  30 . Two of the pins  34  in the first row  30 A are associated with the pins  34  of the seventh connector  32  of the second sub-lead frame  12 B. 
         [0028]    The second row  30 B of pins  34  of the upper connector  30  includes fourteen pins  34 , seven of which are associated with the leads  14  of the first sub-lead frame  12 A, five of which are associated with the leads  14  of the second sub-lead frame  12 B, and two of which are associated with a thermistor  36 , which is located in the first plane  18 A and part of the second sub-lead frame  12 B. The third row  30 C of pins  34  of the upper connector  30  are associated with the pins  34  of the fourth connector  26  and fifth connector  28 . 
         [0029]    The connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  and leads  14  are used for connecting the assembly  10  to various components. In addition to having other types of interfaces than the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32 , the connectors  20 , 22 , 24 , 26 , 28 , 30 , 32  may be used for providing a connection between the lead frame  12 , and various components such as sensors, solenoids, thermistors, and the like. In one embodiment, the lead frame assembly  10  is used as part of a transmission. Each of the leads  14  may be used for connection to a corresponding solenoid, and each of the first three connectors  20 , 22 , 24  may be used for connection with other parts of the transmission. Also, each of the remaining connectors  26 , 28 , 30 , 32  may be used to connect to components outside the transmission, such as an engine controller, a vehicle electronic control unit, or the like. Various components may also be mounted to the lead frame  12 , such as resistors, capacitors, one or more inductors, or as shown in  FIG. 2 , the thermistor  36 . 
         [0030]    The use of the three rows  30 A,B,C as part of the upper connector  30  provides the additional functionality of being able to add the third sub-lead frame  12 C to the first and second sub-lead frames  12 A,B, without having to add an additional connector. More specifically, the design of the lead frame assembly  10  allows for a single corresponding connector to be connected to the upper connector  30  and therefore be in electrical communication with all of the connectors  20 , 22 , 24 , 26 , 28 , 32  and the leads  14  of all three sub-lead frames  12 A, 12 B, 12 C. The upper connector  30  being a three-row connector having additional pins  34  therefore expands the use of the lead frame assembly  10  beyond the use of the two sub-lead frames  12 A, 12 B having the connectors  20 , 22 , 24 , 32 , to having the additional connectors  26 , 28 , providing the lead frame assembly  10  with additional capability, without having to add another connector to supplement the upper connector  30 . 
         [0031]    While is has been shown that the pins  34  in each of the rows  30 A, 30 B, 30 C are associated with the various pins  34  of the connectors  20 , 22 , 24 , 26 , 28 , 32  and leads  14 , as previously described, it is within the scope of the invention that the pins  34  of the connector  30  may be configured differently, and each row  30 A, 30 B, 30 C may have different pins  34  associated with different connectors  20 , 22 , 24 , 26 , 28 , 32  and leads  14 , without departing from the scope of the invention. 
         [0032]    Referring again to the Figures generally, in one embodiment, the fourth connector  26  and the fifth connector  28  are grouped together as a cluster, shown generally at  38 . The cluster  38  is connected to the lead frame  12  through the use of an extension  40 . The extension  40  provides a connection between the portion of the housing  16  which supports the connectors  26 , 28  located in the second plane  18 B and the portion of the housing  16  located in the first plane  18 A. In other embodiments, the connectors  26 , 28  are not arranged in a cluster, but are located in separate locations, and there is a separate extension for each connector  26 , 28 , which is used to support each connectors  26 , 28 . 
         [0033]    Various molding techniques may be used to integrally form the housing  16  with the lead frame  12 . The housing  12  is molded around the lead frame  12 , while still allowing the pins  34  and the leads  14  to remain exposed for connection with the various components as mentioned above. The lead frame  12  may also include die attach pads which are used for supporting the lead frame  12  during assembly. 
         [0034]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.