Patent Publication Number: US-8523581-B2

Title: Header connector assembly

Description:
FIELD OF THE INVENTION 
     The present invention is directed to electrical assemblies, components for electrical assemblies, and processes of fabricating electrical assemblies and components for electrical assemblies. More specifically, the present invention relates to header connector assemblies, components for header connector assemblies, and processes for fabricating such components and assemblies. 
     BACKGROUND OF THE INVENTION 
     Headers for electrical connection are used for various applications. Headers can be used in electrical systems, for example, for vehicles, ships and boats, aerospace systems, electric tools, control systems, or other suitable electric products. Such headers can include a circuit board susceptible to damage upon being exposed to environmental conditions such as temperature changes and/or environmental substances such as moisture. 
     Headers can engage modules for enclosing circuit boards and for electrically connecting the circuit boards to other devices such as controllers, motors, sensors, other modules (for example, control modules), or combinations thereof. The circuit boards can additionally be secured to devices such as headers for interfacing with other electrical components such as plugs, transmitters, signal sources, or other devices for providing electrical signals to the module and/or devices in electrical connection with the module. 
     Known headers suffer from a drawback that they are susceptible to environmental conditions and/or substances affecting the circuit board within the header through unsealed interfaces between headers and modules. Additionally, fabrication of known headers suffers from a drawback that header materials have limited the temperature and methodology for securing the header to the circuit board. 
     Other known headers are damaged during transport. For example, in such known headers, pins or other fragile features can be broken during transport. 
     A header connector assembly and a process of fabricating a header connector assembly that do not suffer from one or more of the above drawbacks would be desirable in the art. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In an exemplary embodiment, a header connector assembly having a header subassembly and a module includes an outer housing and an inner housing, the inner housing having contacts and a circuit board, wherein the circuit board is attached to the header subassembly by being one or more of wave soldered and surface mounted. 
     In another exemplary embodiment, a header connector assembly having a header subassembly and a module includes a header housing and one or more internal connectors. The one or more header internal connectors are positionable within the header housing. 
     In another exemplary embodiment, a process of fabricating a header connector assembly having a header subassembly and a module includes assembling a circuit board on an inner housing of the header connector assembly, installing the inner housing into an outer housing of the header connector assembly, the outer housing having mating interfaces to form the header subassembly, and assembling the header subassembly into the module. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of an exemplary disassembled header connector assembly according to the disclosure. 
         FIG. 2  shows a perspective view of an exemplary disassembled header connector assembly according to the disclosure. 
         FIG. 3  shows an engagement end view of an exemplary header subassembly according to the disclosure. 
         FIG. 4  shows an engagement end view of a header housing for an exemplary header subassembly according to the disclosure. 
         FIG. 5  shows a module end view of a header housing for an exemplary header subassembly according to the disclosure. 
         FIG. 6  shows a header housing end view of internal connectors of an exemplary header subassembly according to the disclosure. 
         FIG. 7  shows a view of a module end view of internal connectors of an exemplary header subassembly according to the disclosure. 
         FIG. 8  shows a cutaway section view of an exemplary assembled header connector assembly according to the disclosure. 
         FIG. 9  shows a cutaway section view of an exemplary assembled header connector assembly according to the disclosure. 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Provided is an exemplary header connector assembly and an exemplary process of fabricating a header connector assembly. Embodiments of the present disclosure are capable of resisting environmental conditions and/or substances by being sealed, are capable of electrically communicating with other electrical components, are capable of interfacing with modules of various designs, are capable of being used with horizontally oriented modules, are capable of being fabricated by various previously unavailable methods, are protected from having components broken during transportation, and combinations thereof. For example, in some embodiments, by separating portions of a header, fabrication and/or transportation can be performed with less risk of damage. Likewise, in some embodiments, additional features such as shrouds protect mating terminals and/or pins by surrounding them. 
     Referring to  FIGS. 1 and 2 , a header connector assembly  100  includes a header subassembly  102 , a seal  118 , and a module  108 . The header subassembly  102  includes an outer housing  302  and an inner subassembly  702 . Upon positioning the header subassembly  102  and the seal  118  within the module  108 , inner subassembly  702  is sealed from moisture or other environmental substances and/or conditions. The outer housing  302  remains exposed to the environment upon assembly. In one embodiment, the header subassembly  102  is mounted within the module  108  in a horizontal direction. As used herein, the term “horizontal,” or grammatical variations thereof, refers to a direction or orientation parallel with the surface of a circuit board  106  such as a printed circuit board. For example, a direction horizontal with the circuit board  106  is in a plane parallel to the surface of the circuit board  106 . In one embodiment, the module  108  includes circuit board alignment features  107  (see  FIGS. 8 and 9 ) arranged and disposed for horizontal insertion of the circuit board  107  (see  FIGS. 8 and 9 ) into the module  108 . In one embodiment, the module  108  is capable of being a part of an electrical system, for example, for vehicles, ships and boats, aerospace systems, electric tools, control systems, or other suitable electric products. In one embodiment, the module is a seat-weight sensor module. Input from seat-weight sensors are processed and sent to a main airbag control module (not shown) that determines whether or not an airbag (not shown) should be deployed and with what force it should be deployed. 
     The seal  118  includes an elastomeric material (for example, a silicon rubber) having module ribbed sections  112  for facilitating a seal when assembled. The elastomeric material is positioned within a shroud  104  of the header subassembly  102 , as in the embodiment shown in  FIG. 2 , or surrounds the shroud  104  as in the embodiment shown in  FIG. 1 . The header connector assembly  100  includes module engagement features  110  which are any suitable features permitting a sealed or substantially sealed engagement between the header subassembly  102 , the seal  118 , and the module  108 . Suitable features include, but are not limited to, one or more ribbed sections  112  (see  FIG. 1 ) for facilitating an interference fit and/or one or more clipping mechanisms  114  (see  FIG. 2 ) for facilitating a mechanical engagement. The engagement features  110  maintain the header connector assembly  100  in a sealed condition upon being assembled. 
     Referring to  FIGS. 1 and 2 , in one embodiment, the seal  118  is made of the elastomeric material. In this embodiment, the seal  118  is a substantially rectangular geometry corresponding to the size and geometry of the module  108  and/or the shroud  104  of the header subassembly  102 . The ribbed sections  112  are capable of being positioned within the module  108  and, upon assembly, the seal  118  abuts the module  108  to form a seal. Referring to  FIGS. 1 and 9 , in a further embodiment, the abutting of the module  108  is on a predetermined amount of planes or surfaces (for example, at least three, at least six, at least nine, or at least twelve) and extends external to the header connector assembly  100 . In one embodiment, the module  108  includes corresponding features (not shown) for engaging the header subassembly  102 . 
     Referring to  FIGS. 1 and 2 , the seal  118  further includes a header engagement feature  120  capable of forming an interference fit with the header subassembly  102 . The header engagement feature  120  is any suitable feature capable of engaging the header subassembly  102 . Suitable features include, but are not limited to, one or more peripheral seals  122  (see  FIG. 1 ), keying features, one or more clipping mechanisms, threaded or partially threaded portions, tapered sections, fasteners (for example, bolts, screws, adhesive, magnets, other mechanical fastening features, and combinations thereof), other suitable securing features, or combinations thereof. 
     To assemble the embodiment of the header connector assembly  100  shown in  FIG. 1 , the header subassembly  102  is positioned within the seal  118  so that a tight interference fit and/or mechanical engagement is formed between the seal  118  and the shroud  104  of the header subassembly  102 . The header subassembly  102  and the seal  118  are then inserted into the module  108 . In one embodiment, the seal  118  is positioned around the header subassembly  102  and inserted into the module  108  together. In another embodiment, the header subassembly  102  is inserted into the module  108  and then the seal  118  is around the header subassembly  102 . 
     Upon being assembled, as shown in the cutaway section view of  FIG. 8 , the embodiment of the header connector assembly  100  shown in  FIG. 1  is capable of providing electrical signals and/or power from the electrical device or mating connector (not shown) to the module  108  (see  FIG. 1 ). As shown in  FIG. 8 , in one embodiment, the seal  118  is completely within the shroud  104  and encloses the internal connectors  210 , thereby protecting the contacts  126  and/or the circuit board  106 . 
     Referring to  FIGS. 1 and 2 , the header subassembly  102  includes the outer housing  302  and an inner subassembly  702 . The outer housing  302  includes a mating end  303  and a mounting end  305 . One or more enclosures or mating interfaces  124  extend from the mating end  303  for attachment and/or mating to one or more mating connectors (not shown) or other devices (not shown). The shroud  104  surrounds the outer housing  302  at the mounting end  305 . The mating interfaces  124  are sized and shaped to enclose internal connectors  210  wherein each internal connector  210  supports one or more contacts  126  such as electrically conductive leads, pins, or other suitable conductive structures. The one or more contacts  126  are attached to the circuit board  106 , for example, by wave soldering, press fitting, surface mounting, other suitable securing mechanisms, or combinations thereof. 
     Referring to  FIG. 2 , in one embodiment, the outer housing  302  includes the module engagement features  110 . Upon assembly, the seal  118  abuts the module  108  and, in one embodiment, is completely enclosed by the shroud  104 . For example, in this embodiment, the seal  118  is within the shroud  104 . In one embodiment, the shroud  104  and/or the seal  118  further includes the header engagement features  120  capable of forming an interference fit with the header subassembly  102 . The header engagement features  120  are any suitable features capable of engaging the header subassembly  102 . Suitable features include, but are not limited to, keying features  202 , one or more of the peripheral seals, one or more clipping mechanisms, threaded or partially threaded portions, tapered sections, fasteners (for example, bolts, screws, adhesive, magnets, other mechanical fastening features, and combinations thereof), other suitable securing features, or combinations thereof. 
     In one embodiment, the module  108  includes corresponding features such as mating features  116  for engaging the shroud  104 , a header housing  204  having the shroud  104 , and/or the seal  118 . Such corresponding features are capable of being positioned on the inside of the module  108  and/or on the outside of the module  108 . 
       FIG. 3  shows a view from the mating end  303  of an exemplary embodiment of the header subassembly  102 . Consistent with the embodiment shown in  FIG. 1 , in this embodiment, the header subassembly  102  is a unitary structure secured to the circuit board  106  (see  FIG. 1 ) and including one or more mating interfaces  124  configured to engage electrical devices (not shown) and/or mating connectors (not shown) such as harness connectors, plugs, transmitters, signal sources, or other components for providing electrical signals and/or power to the module  108  and/or components (not shown) in electrical connection with the module  108  (see  FIG. 1 ). Although shown with three mating interfaces  124  in  FIG. 3 , other embodiments of the header subassembly  102  include one mating interface  124 , two mating interfaces  124 , or more than three mating interfaces  124 . As shown in  FIG. 3 , in one embodiment, each of the mating interfaces  124  includes a cuboid perimeter  304  extending around the contacts  126  protruding from within the header subassembly  102 . The header subassembly  102  further includes channels  308  or slots, one or more recesses  310 , and one or more protrusions  312  for releasable securing of the header subassembly  102  to the mating connectors (not shown). 
       FIG. 4  shows a view from the mating end  303  of an exemplary embodiment of the header subassembly  102 . In one embodiment, the header subassembly  102  is or includes a material capable of being damaged by wave soldering and/or surface mounting (for example, the seal  118  and/or the elastomeric material). As shown in  FIG. 2 , in one embodiment having such capabilities, the header subassembly  102  is a two-part structure including the header housing  204  and the internal connectors  210 . 
     The header housing  204  includes the one or more mating interfaces  124  capable of engaging mating connectors (not shown) such as harness connectors, plugs, transmitters, signal sources, or other components for providing electrical signals to the module  108  and/or components (not shown) in electrical connection with the module  108 . Although the embodiment shown in  FIG. 2  includes three mating interfaces  124 , in other embodiments, only one mating interface  124 , only two mating interfaces  124 , or more than three mating interfaces  124  are included in the header housing  204 . As shown in  FIG. 4 , in one embodiment, each of the mating interfaces  124  includes the cuboid perimeter  304  extending around an open region  402  devoid of pins when unassembled. The mating interfaces  124  further include channels  308  or slots, one or more recesses  310 , and a protrusion  312  for releasable securing of the mating interfaces  124  to the mating connectors (not shown). 
       FIG. 5  shows a view from a mounting end  305  of the header housing  204 . The mounting end  305  of the header housing  204  shows the keying features  202  for engaging the internal connectors  210  (see  FIG. 2 ) and the module engagement features  110  including the clipping mechanisms  114  capable of engaging the mating features  116  (see  FIG. 2 ) of the module  108  (see  FIG. 2 ). In one embodiment, the clipping mechanisms  114  are capable of being positioned within the mating features  116  (see  FIG. 2 ) of the module  108 , thereby securing the shroud  104  (see  FIG. 2 ) to the module  108  (see  FIG. 2 ). In addition to the keying features  202  and a clipping member  506  for engagement, the header housing  204  further includes an interior chamber  208  configured to receive the internal connectors  210  (see  FIG. 2 ) of the header subassembly  102 . In one embodiment, the interior chamber  208  is a unitary chamber, such as, a substantially rectangular recess, for receiving a plurality of internal connectors  210  (see  FIG. 2 ) of the header subassembly  102  (see  FIG. 2 ). In another embodiment, the interior chamber  208  includes individual sub-chambers (not shown), such as cuboid recesses, corresponding to the number of the internal connectors  210  (see  FIG. 2 ) in the header subassembly  102 . The header housing  204  further includes other suitable features for releasably securing the internal connectors  210  (see  FIG. 2 ) of the header subassembly  102  (see  FIG. 2 ). 
       FIG. 6  shows a view from a header housing end  602  of the internal connectors  210  of the inner housing consistent with the embodiment shown in  FIG. 2 . In this embodiment, the internal connectors  210  include geometric features such as curved corners  212  corresponding to the interior chamber(s)  208  (see  FIG. 5 ), alignment channels  214  corresponding to the keying features  202  (see  FIG. 5 ), securing mechanisms  216  for releasably (for example, manually or with a tool) or permanently engaging a feature in the header housing  204  (for example, a clipping member  506  as shown in  FIG. 5 ), other suitable alignment and/or securing features, or combinations thereof. 
       FIG. 7  shows a view of a module end  307  of an exemplary embodiment of the inner subassembly  702  consistent with the embodiment shown in  FIG. 2 . In this embodiment, the internal connectors  210  are secured to the circuit board  106  (see  FIG. 2 ), for example, through a fastener  704  such as a screw, a detent, a bolt, or other securing mechanism. Contacts  126  extend from the header housing  204 , through the internal connectors  210 , and into the circuit board  106  (see  FIG. 2 ). The contacts  126  extend through the internal connectors  210  into the header housing  204  when the header subassembly  102  (see  FIG. 2 ) is assembled. In the embodiment with the contacts  126  secured by wave soldering and/or surface mounting, internal connectors  210  of the header subassembly  102  are devoid of material capable of being damaged by wave soldering and/or surface mounting. In a further embodiment, the header housing  204  (see  FIG. 2 ) includes material capable of being damaged by wave soldering and/or surface mounting, for example, the seal  118 . In this embodiment, the header housing  204  is assembled with internal connectors  210  of the header subassembly  102  after any wave soldering and/or surface mounting is completed. 
     Referring again to  FIG. 2 , in an exemplary process of fabricating the header connector assembly  100 , the header subassembly  102  is positioned on the circuit board  106  and secured to the circuit board  106 . The header subassembly  102  is secured to the circuit board  106  through any suitable securing method. Suitable securing methods include, but are not limited to, wave soldering, press fitting, surface mounting, or other suitable combinations thereof. The header subassembly  102  is then inserted through the shroud  104 . The header subassembly  102  and the shroud  104  are then inserted in a horizontal direction into the module  108  where the circuit board  106  is secured and/or electrically connected and where the ribbed section  112  forms a tight interference fit with the module  108 . In this embodiment, the shroud  104  is separate from the header subassembly  102 . In another similar embodiment, the shroud  104  is positioned around the header subassembly  102  and inserted into the module  108 . 
     Upon being assembled, as shown in the cutaway section view of  FIG. 9 , the header connector assembly  100  shown in  FIG. 2  is capable of providing electrical signals and/or power from the electrical component (not shown) to the module  108  (see  FIG. 2 ). In one embodiment the module is electrically or mechanically connected to other suitable components such as controllers, motors, sensors, other modules (for example, control modules), or combinations thereof. The seal  118  extends to the exterior of the connector assembly  100  and the internal connector (s)  210  are enclosed, thereby protecting the contacts  126  and/or the circuit board  106 . 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.