Patent Publication Number: US-9837773-B2

Title: Electrical connector

Description:
FIELD 
     The present disclosure relates to an electrical connector and a method for assembling an electrical connector assembly. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     For many years, motor vehicles have included an on board computer system. As these systems have developed and their capabilities have increased, devices have been developed to communicate with and receive information from a vehicle&#39;s computer system, including diagnostic information, driver habit information, and drive parameter information. These devices are commonly small pieces of hardware that may be connected to a motor vehicle to provide additional functionality to the vehicle&#39;s computer system or receive information. These devices may be connected to a vehicle via the vehicle&#39;s On-Board Diagnostic port or a similar connection port. These devices typically include a circuit board for transferring information and signals between circuit components and external devices, pins for electrically connecting the circuit board to an external device, and a housing to protect the circuit board. 
     Despite the satisfactory performance of conventional electrical connectors and component configurations for such devices, there is constantly a desire to reduced cost and increase ease of assembly, while providing a desirable durability, low warranty claim, and compliance with performance requirements. 
     SUMMARY 
     The present disclosure provides an electrical connector and a method for assembling an electrical connector assembly capable of reducing the cost and increasing the ease of assembly while maintaining the durability and functionality of the device. 
     According to one form of the present disclosure, an electrical connector includes a plurality of connector units each having a base formed of a first arm and a second arm. The first arm and second arm of each connector unit may be joined together by a cross member. For each connector unit, a first pin is integrally formed with and extends from a first end of the first arm. The first pin of each connector unit has a soldering portion and a blade portion. Additionally, a second pin is integrally formed with and extends from a second end of the first arm of each connector unit. Each connector unit also has a soldering pad integrally formed with and extending from a first end of the second arm. The soldering portion and the soldering pad of each connector unit are configured to be soldered to a printed circuit board to attach the electrical connector to the printed circuit board. Additionally, a bridge is integrally formed with and extends between the first arm of one connector unit and the second arm of another connector unit, thereby linking the plurality of connector units together to form an array of connector units. Each bridge and a portion of the first arm of each connector unit are configured to be cut out such that two rows of electrically independent pins are arranged on the printed circuit board. 
     According to one aspect of the present disclosure, the electrical connector may further include a fixturing tab integrally formed with and extending from the base of the first connector unit in the array of connector units. A second fixturing tab may also be integrally formed with and extend from the base of the last connector unit in the array of connector units. The fixturing tabs may be used to locate the electrical connector relative to the printed circuit board when positioning the electrical connector on the printed circuit board for soldering. 
     According to another aspect of the present disclosure the electrical connector may include a plastic carrier. In such an embodiment, the base of each connector unit is embedded in a plastic material that forms the plastic carrier. The plastic carrier embeds the base of each connector unit such that a first surface of each connector unit base remains uncovered by the plastic material of the plastic carrier. In other words, the surface of the connector unit that is opposite the pins remains exposed and uncovered by the plastic carrier. The plastic carrier may further embed the soldering portion and the soldering tab of each connector unit while leaving a soldering surface of each soldering portion and soldering pad exposed. According to yet another aspect of the present disclosure, the plastic carrier may include a fixturing tab to assist with locating the electrical connector relative to the printed circuit board. According to another form of the present disclosure, the plastic carrier may define a plurality of apertures that extend through a thickness of the plastic carrier. Each aperture may be positioned such that the bridge and the portion of the first arm of each connector unit that are configured to be cut out are not embedded in the plastic carrier. 
     Another aspect of the present disclosure includes the electrical connector installed in a housing. The housing may include a wall that defines a plurality of apertures through which the pins of the electrical connector may be inserted. The housing may further include a first shell piece and a second shell piece. The second shell piece may include a shelf that protrudes from the second shell piece. The first shell piece and second shell piece may be joined together and joined with the wall. Joined together, the wall, first shell piece, and second shell piece define a cavity into which the shelf protrudes. The cavity may further house the printed circuit board. The shelf may abut the first surface of the base of each connector unit to lock the electrical connector against the wall. 
     According to another form of the present disclosure, an electrical connector assembly includes a single printed circuit board, a first row of electrically independent pins, and a second row of electrically independent pins. Each pin of the first row of pins has a soldering portion and a blade portion. Each soldering portion may be soldered to the printed circuit board. Additionally, each pin of the second row of pins has a soldering pad, a blade portion, and an arm portion. The arm portion of each pin of the second row of pins is integrally formed with both the soldering pad and blade portion of each second row pin to connect the soldering pad and blade portion of each of the second row pins. Additionally, each soldering pad may be soldered to the printed circuit board. 
     According to yet another form of the present disclosure, a method for manufacturing an electrical connector assembly includes providing an electrical connector as described above. The method further includes embedding the base of each of the connector units in a plastic carrier such that a first surface of each connector unit base remains uncovered by the plastic carrier. As described above, the plastic carrier may define a plurality of apertures that extend through a thickness of the plastic carrier. Each aperture is positioned such that the bridge and a portion of the first arm of each connector unit are not embedded in the plastic carrier. The method further includes shearing off the bridge and the portion of the first arm of each connector unit that are not embedded in the plastic carrier. The method continues by positioning the electrical connector embedded in the plastic carrier on a printed circuit board such that the soldering portion of each connector unit and the soldering pad of each connector unit are in contact with the printed circuit board to form a pre-soldering assembly. Next, the method includes passing the pre-soldering assembly through a reflow oven to solder the soldering portions and soldering pads to the printed circuit board. 
     Further aspects of the disclosure are explained in greater detail below by means of preferred illustrative embodiment with reference to the attached drawings. The drawings are provided for purely illustrative purposes and are not intended to limit the scope of the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further details of the disclosure are described in more detail with reference to the drawings, in which: 
         FIG. 1  is a perspective view of an electrical connector in accordance with a form of the present disclosure; 
         FIG. 2  is an alternate perspective view of the electrical connector of  FIG. 1 ; 
         FIG. 3  is a perspective view of an electrical connector embedded in a plastic carrier in accordance with a form of the present disclosure; 
         FIG. 4 a    is a top view of the electrical connector embedded in a plastic carrier of  FIG. 3 ; 
         FIG. 4 b    is a top view of the electrical connector of  FIG. 4 a    after portions of the electrical connector are removed; 
         FIG. 5  is a perspective view of an electrical connector assembly in a housing in accordance with a form of the present disclosure; and 
         FIG. 6  shows the steps of a method for manufacturing an electrical connector assembly in accordance with a form of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     The present disclosure provides an electrical connector and a method for assembling an electrical connector assembly. 
     Referring first to  FIGS. 1 and 2 , an electrical connector  10  includes a plurality of connector units  12  each having a base  14  formed of a first arm  16  and a second arm  18 . Each base  14  may be substantially U-shaped. The first arm  16  and second arm  18  of each connector unit  12  may be joined together by a cross member  20 . For each connector unit  12 , a first pin  22  is integrally formed with and extends from a first end  24  of the first arm  16 . The first pin  22  may be substantially perpendicular to the first arm  16  from which it extends. The first pin  22  of each connector unit  12  has a soldering portion  26  and a blade portion  28 . The blade portion  28  of each of the first pins  22  is configured to make contact and thereby electrically connect with a connector or port of an external device or cable. The soldering portion  26  of each of the first pins  22  is configured to be soldered to a printed circuit board  40 . Each connector unit  12  also includes a second pin  30  that is integrally formed with and extends from a second end  32  of the first arm  16  of each connector unit  12 . The second pin  30  may be substantially perpendicular to the first arm  16  from which it extends. Each connector unit  12  also has a soldering pad  34  integrally formed with and extending from a first end  36  of the second arm  18 . The soldering pad  34  may be substantially perpendicular to the second arm  18  from which it extends. Individual connector units  12  of the electrical connector  10  may be linked together by a bridge  38  such that a bridge  38  links two connector units  12  together. Each bridge  38  may be integrally formed with and extend between the first arm  16  of one connector unit  12  and the second arm  18  of another connector unit  12 . Accordingly, bridges  38  may link all successive connector units  12  of the plurality of connector units, thereby linking the plurality of connector units  12  together to form an array or chain of connector units. Accordingly, the electrical connector  10  may be a single unitary piece formed of an electrically conductive material, such as brass. 
     Each bridge  38  and a portion of the first arm  16  of each connector unit  12  are configured to be cut out. Specifically, each bridge  38  and the portion of the first arm  16  to which each bridge  38  connects may be cut, sheared, or punched out to remove the material making up the bridge  38  and each respective portion of the first arms  16 . Removing such material from the electrical connector  10  creates two rows of electrically independent pins are arranged on the printed circuit board  40 . The first row of pins including the first pins  22  of each of the connector units  12  and the second row of pins including the second pins  30  of each of the connector units  12 . 
     The pins  22 ,  30  of the electrical connector  10  may be of unequal lengths such that some pins  22 ,  30  have a length of L while other pins  22 ,  30  have a length of L′. The pins  22 ,  30  may have a constant cross-sectional area C along the entire length L, L′ of the pin  22 ,  30 . Alternatively, the first pins  22  may have a non-constant cross-sectional area. For example, the blade portions  28  of the first pins  22  may have a first cross-sectional area C, while the soldering portions  26  of the first pins  22  may have a second cross-sectional area C′. The cross-sectional area C′ of the soldering portions  26  of the first pins  22  may be substantially equal to a cross-sectional area C′ of the soldering pads  34 . Additionally, the pins  22 ,  30  may end in a tapered point  23 . 
     The electrical connector  10  may be thought of as a surface mount electronic component for use with a circuit board. To mount or attach the electrical connector  10  a printed circuit board  40 , the soldering portion  26  and the soldering pad  34  of each connector unit  12  are configured to be soldered to a printed circuit board  40 . The soldering portions  26  and the soldering pad  34  of the electrical connector  10  may be soldered to the printed circuit board  40  using a surface mount technology soldering machine or a reflow oven. 
     According to one aspect of the present disclosure, the electrical connector  10  may further include a first fixturing tab  42 . The first fixturing tab  42  may be further integrally formed with and extend from the base  14  of the first connector unit in the array of connector units  12 . A second fixturing tab  43  may also be integrally formed with and extend from the base  14  of the last connector unit in the array of connector units  12 . In other words, the fixturing tabs  42 ,  43  may be placed at the outside ends of the electrical connector  10 . The fixturing tabs  42 ,  43  may be used to locate the electrical connector  10  relative to the printed circuit board  40  when positioning the electrical connector  10  on the printed circuit board  40  for soldering. 
     As shown in  FIGS. 3, 4   a , and  4   b , the electrical connector  10  may include a plastic carrier  44 . In such an embodiment, the base  14  of each connector unit  12  is embedded in a plastic material that forms the plastic carrier  44 . The plastic carrier embeds the base  14  of each connector unit  12  such that a first surface  46  of each connector unit base  14  remains uncovered by the plastic material of the plastic carrier. In other words, the surface  46  of the connector unit  12  that is opposite the pins  22 ,  30  remains exposed and uncovered by the plastic carrier  44 . The plastic carrier  44  may further embed the soldering portion  26  and the soldering pad  34  of each connector unit  12  while leaving a soldering surface  48  of each soldering portion  28  and soldering pad  34  exposed. The plastic carrier  44  may include at least one fixturing tab  50  to assist with locating the electrical connector  10  relative to the printed circuit board  40 . According to another form of the present disclosure, the plastic carrier  44  may define a plurality of apertures  52 . The apertures  52  may extend through a thickness T of the plastic carrier  44 . As best shown in  FIG. 4 a   , each aperture  52  may be positioned such that the bridge  38  and the portion of the first arm  16  of each connector unit  12  that are configured to be cut out are positioned within the aperture  52  and are not embedded in the plastic carrier  44 . Leaving bridges  38  and the portions of the first arms  16  that are to be cut out exposed rather than embedding these areas in the plastic carrier  44  allows for a clean cut or punch.  FIG. 4 b    shows the electrical connector  10  embedded in the plastic carrier  44  after the portions of the bridges  38  and the first arms  16  initially positioned in the apertures  52  have been removed. The first surface  46  of the base  14  of each connector unit  12  may extend beyond the plastic carrier  44  such that the metal of the first surfaces  46  may rest directly on the machine used to cut or punch out the unembedded bridges  38  and the portions of the first arms  16  without interference from the plastic carrier. 
     The thickness T of the plastic carrier  44  may be such that the plastic carrier  44  extends from the first surface  46  of the base  14  to the area where the soldering portion  26  transitions to the blade portion  28  of each first pin  22 . The plastic carrier  44  may be formed of a plastic material by an over molding or injection molding process. The plastic material of the plastic carrier  44  may be sufficiently durable to withstand being passed through a reflow oven during the process of soldering the electrical connector  10  to the printed circuit board  40 . 
     According to  FIG. 5 , the electrical connector  10  may be installed in a housing  54 . The housing  54  may include a wall  56  that defines a plurality of apertures  58  through which the pins  22 ,  30  of the electrical connector  10  may be inserted. The housing  54  may further include a first shell piece  60  and a second shell piece  62 . The second shell piece may include a shelf  64  that protrudes from the second shell piece  62 . The first shell piece  60  and second shell piece  62  may be joined together and joined with the wall  56 . Joined together, the wall  56 , first shell piece  60 , and second shell piece  62  define a cavity  66  into which the shelf  64  protrudes. The cavity  66  may further house the printed circuit board  40 . The shelf  64  may abut the first surface  46  of the base  14  of each connector unit  12  to lock the electrical connector  10  against the wall  56 . The housing  54  may protect the printed circuit board  40  while the interaction of the wall  56  and the shelf  64  retain the electrical connector  10  and isolate the printed circuit board  40  from forces applied to the pins  22 ,  30  as the electrical connector  10  is attached and detached to external components. 
     The electrical connector may be connected to a vehicle via the vehicle&#39;s On-Board Diagnostic port or a similar connection port. Connecting the electrical connector to the vehicle via the On Board Diagnostic port powers the printed circuit board via the electrical connector and facilitates communications to and from the vehicle&#39;s computer system. 
     According to another form of the present disclosure, an electrical connector assembly  70  includes a single printed circuit board  40 , a first row of electrically independent pins  22 , and a second row of electrically independent pins  30 . Each pin of the first row of pins  22  has a soldering portion  26  and a blade portion  28 . Each soldering portion  26  may be soldered to the printed circuit board  40 . Additionally, each pin of the second row of pins  30  has a soldering pad  34 , a blade portion  31 , and an arm portion  18 . The arm portion  18  of each pin of the second row of pins  22  is integrally formed with both the soldering pad  34  and blade portion  31  of each second row pin  22  to connect the soldering pad  34  and blade portion  31  of each of the second row pins  22 . Additionally, each soldering pad  34  may be soldered to the printed circuit board  40 . The first row of pins  22  and the soldering pads  34  of the second row of pins  30  may be substantially coplanar. The soldering pads  34  of the pins of the second row of electrically independent pins  22  and the blade portion  31  of each pin of the second row of pins  22  may be substantially non-coplanar. In other words, the soldering pads  34  of the pins of the second row of pins  22  may be parallel to the blade portions  31  of the pins of the second row of pins  22  and spaced apart from the blade portions  31  of the pins of the second row of pins  22  by the arm portion  18  of each pin of the second row of pins  22 . 
     The electrical connector assembly comprising the electrical connector  10  and the printed circuit board  40  may be installed in a housing  54 . The housing  54  may include a wall  56  that defines a plurality of apertures  58  through which the pins  22 ,  30  of the electrical connector  10  may be inserted. The housing  54  may further include a first shell piece  60  and a second shell piece  62 . The second shell piece may include a shelf  64  that protrudes from the second shell piece  62 . The first shell piece  60  and second shell piece  62  may be joined together and joined with the wall  56 . Joined together, the wall  56 , first shell piece  60 , and second shell piece  62  define a cavity  66  into which the shelf  64  protrudes. The cavity  66  may further house the printed circuit board  40 . The shelf  64  may abut the first surface  46  of the base  14  of each connector unit  12  to lock the electrical connector  10  against the wall  56 . The housing  54  may protect the printed circuit board  40  while the interaction of the wall  56  and the shelf  64  retain the electrical connector  10  and isolate the printed circuit board  40  from forces applied to the pins  22 ,  30  as the electrical connector  10  is attached and detached to external components. 
     As shown in  FIG. 6 , a method for manufacturing an electrical connector assembly  70  includes providing an electrical connector S 100  as described above. Specifically, the electrical connector  10  may include a plurality of connector units  12  each having a base  14  formed of a first arm  16  and a second arm  18 . The first arm  16  and second arm  18  may be joined together by a cross member  20 . Each connector unit  12  further having a first pin  22  integrally formed with and extending from a first end  24  of the first arm  16 , a second pin  30  integrally formed with and extending from a second end  32  of the first arm  16 , and a soldering pad  34  integrally formed with and extending from a first end  36  of the second arm  18 . The first pin  22  having a soldering portion  26  and a blade portion  28 . A bridge  38  may be integrally formed with and extend between the first arm  16  of one connector unit  12  and the second arm  18  of another connector unit  12  thereby linking the plurality of connector units  12  together to form an array of connector units  12 , as described above. 
     The method further includes embedding S 200  the base  14  of each of the connector units  12  in a plastic carrier  44  such that a first surface  46  of each connector unit base  14  remains uncovered by the plastic carrier  44 . As described above, the plastic carrier  44  may define a plurality of apertures  52  that extend through a thickness T of the plastic carrier  44 . Each aperture  52  is positioned such that the bridge  38  and a portion of the first arm  16  of each connector unit  12  are not embedded in the plastic carrier  44 . 
     The method further includes removing S 300  the bridge  38  and the portion of the first arm  16  of each connector unit  12  that are not embedded in the plastic carrier  44 . The bridges  38  and the portions of the first arms  16  to which the bridges  38  are attached may be punched, cut, sheared, or stamped out in order to be removed. These areas not being embedded in the plastic carrier  44  allows for cleaner removal. 
     The method continues by positioning S 400  the electrical connector  10  embedded in the plastic carrier  44  on a printed circuit board  40  such that the soldering portion  26  of each connector unit  12  and the soldering pad  34  of each connector unit  12  are in contact with the printed circuit board  40 . This arrangement of the electrical connector  10  positioned relative to the printed circuit board  40  forms a pre-soldering assembly. Positioning S 400  the electrical connector  10  embedded in the plastic carrier  44  on a printed circuit board  40  may include employing a fixturing tab  50  integrally formed with the plastic carrier  44  to locate the electrical connector  10  relative to the printed circuit board  40 . 
     The method further includes passing S 500  the pre-soldering assembly through a reflow oven to solder the soldering portions  26  and soldering pads  34  to the printed circuit board  40 . 
     The method may further include inserting S 600  the pins  22 ,  30  through a plurality of apertures  58  defined in a wall  56  of a housing  54  such that the plastic carrier  44  abuts the wall  56  of the housing  54  thereby retaining the pins  22 ,  30  relative to the wall  56 . The method may also include connecting a first shell piece  60 , a second shell piece  62 , and the wall  56  such that the first shell piece  60 , the second shell piece  62 , and the wall  56  enclose the printed circuit board  40  and the plastic carrier  44  of the electrical connector  10  within the housing  54  and a shelf  64  protruding from the second shell piece  62  abuts the plastic carrier  44  thereby locking the plastic carrier  44  against the wall  56 . 
     While the above description constitutes the preferred embodiments of the present disclosure, it will be appreciated that the disclosure is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.