Abstract:
A smart connector for automotive accessories comprising injection molded plastic first and second components, the first component being adapted to receive a printed circuit board with edge contacts therein. Multiple position assurance features are provided so that the PCB can only be fully inserted in the proper orientation and can only be latched in place if fully inserted. Spring terminals are crimped to the wires leading to and from the connector assembly and contactingly engage the edge contacts on the surfaces of the PCB adjacent the leading and trailing edges thereof. The first and second connector components are releasably latched together by means of an exterior detent and spring arm combination.

Description:
FIELD OF THE INVENTION 
   This invention relates to releasably mating electrical connectors for establishing a circuit between a power and/or command signal source and a utilization device and more specifically to a connector assembly comprising releasably matable members adapted to incorporate a printed circuit board having edge connectors therewithin so as to provide intelligence in the circuit. 
   BACKGROUND OF THE INVENTION 
   It is becoming more common to use microprocessors, microcontrollers and the like in the electrical circuits found in automobiles to provide sophisticated control functions. One way to achieve this objective is disclosed in the co-pending application for U.S. patent Ser. No. 10/055,563 for “Scalable, Modular Architecture For Automotive Power Distribution And Body Control Functions,” filed Jan. 23, 2002, and assigned to Yazaki North America, Inc. Another way is to use a so-called “smart connector”; i.e., a connector which incorporates a chip to provide intelligence in the connector itself. This approach has involved the use of lead frames which are complex and costly. 
   SUMMARY OF THE INVENTION 
   The present invention provides an electrical connector having releasably matable first and second connector components designed to incorporate therein a printed circuit board (PCB) having flush edge connectors and being capable of carrying intelligent components such as microprocessors, microcontrollers and the like. The connector assembly of the present invention provides structure to ensure that the PCB is properly oriented and fully inserted into the connector bodies. The assembly is particularly useful in automotive circuits, such as those found between a power source and, for example, a remote controlled mirror mounted on the automotive body. The invention, as will be apparent to those skilled in the art, is useful in applications other than the control of automotive utilization devices. 
   In general, the preferred embodiment of the invention comprises complementally releasably matable first and second connector bodies made of an injection molded plastic such as polyethylene. Each of the matable connectors is hollow and has laterally opposite guide channels to receive the opposite side edges of a small circuit board. Each of the connector bodies is molded to define a plurality of axially oriented and parallel channels receiving spring type electrical terminals which can be crimped onto the stripped ends of wires. The spring portion of the terminals is designed and oriented to engage flush edge contacts on a PCB mounted within the hollow interior volume defined by the connector bodies. Position assurance features are provided to ensure that the PCB is both properly oriented and fully inserted into the first connector body interior. 
   In the preferred form, the connector assembly is provided with latch means having first and second complementally interengaging portions on the exterior surfaces of the first and second connector components, respectively, to releasably latch the bodies together when telescopically engaged. In addition, the assembly comprises a first security feature which is applied to the first connector body after assembly to ensure that the PCB remains in the fully inserted position and does not move back toward the direction in which removal normally occurs. An additional security feature is preferably provided to work in combination with a PCB edge detent structure to lock the PCB in place. 
   Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
     The description herein makes reference to the accompanying drawing wherein like reference numerals refer to like parts throughout the several views, and wherein: 
       FIG. 1  is a perspective view of a connector device embodying the invention; 
       FIG. 2  is an exploded perspective view of the device of  FIG. 1  from the bottom; 
       FIG. 3  is a sectional view of the device showing the crimped terminals and the security locking, detection and protection features; 
       FIG. 4  is a sectional view of the device in the assembled state; 
       FIG. 5  is a sectional plan view showing the PCB layout and a second security means; and 
       FIG. 6  is a view of the complemental open ends of the connector bodies with some interior features removed for simplicity. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to the drawing, the connector assembly of the present invention is shown to comprise a molded plastic first connector  10 , a molded plastic second connector  12  which slides into and latches to the first connector  10  and a printed circuit board  14  (PCB) having flush edge contacts  16  deposited or otherwise formed at the longitudinally opposite edges thereof to provide electrical circuits to intelligent components mounted on the PCB  14 ; examples include microprocessors, microcontrollers and components which are auxiliary thereto. Wires  20  bring power and ground and control or command signals into the second connector  12  and, through terminals to be described, to the PCB components as well. Wires  18  connect the power and ground and output control or command signals to a utilization device such as a remote control automotive mirror. 
   A latch feature  22  is integrally molded to the top surface of the first connector  10  and a complemental latch structure  24  is provided on the top surface of the second connector  12 . Although the latches  22  and  24  may be of any number of different configurations, the present illustration provides an easily manipulated spring latch which permits the connectors  10  and  12  to be securely joined yet permits simple and easy release to separate the connectors  10  and  12  when desired. The latch feature  22  comprises a detent feature  26  integrally molded on the inside surface thereof and the complemental latch structure  24  comprises a spring arm  30  having a cam surface  28  which guides the detent  26  into a hole or aperture in the spring arm and holds it in place when the connectors  10  and  12  are coupled. A supplemental lock piece  27  shown in  FIG. 2  may be inserted into the latches  22 ,  24  to prevent operation thereof. Acting as a connector position assurance device, the lock piece  27  detects incompletely mated connectors. If the supplemental lock piece  27  is not in place, pushing the spring arm  30  downwardly permits the connectors  10  and  12  to be taken apart. 
   As best shown in  FIGS. 1 and 6 , the first connector  10  is preferably injection molded of a suitable plastic such as polyethylene into a doubly truncated cylindrical shape and is provided with longitudinally extending guide ribs  32  on laterally opposite interior surfaces to provide channels which receive and guide the PCB  14  into the interior volume of the first connector  10 . The length of the connector  10  along its axis of symmetry is only slightly greater than that of the PCB  14  as shown in FIG.  4 . As shown in  FIG. 6 , the second connector  12  has guide channels  35  formed therein to receive the PCB  14  when the second connector  12  is inserted into the connector  10 . 
   To ensure that the PCB  14  is properly oriented when inserted into the interior volume of the first connector  10 , a slot  37 , as best shown in  FIGS. 2 and 5 , is formed off-center in the leading edge of the PCB. A longitudinally extending rib  34  on the interior of the first connector fits snugly into the slot  37  only if the PCB  14  is inserted in the proper orientation; i.e., if it is inverted end for end, the rib  34  will hit the edge of the PCB  14  and not allow it to be fully inserted. Similarly, if the PCB  14  is rotated 180° about its longitudinal axis, the off-set nature of the rib  34  in the slot  37  will be such that again the PCB  14  can not be fully inserted. Only if in the proper orientation can the PCB  14  be fully inserted into the first connector  10 . 
   Once the PCB  14  is fully and properly inserted in the correct orientation, a first position assurance latch  36  can be inserted into an opening  39  in the bottom of the first connector  10  as best shown in FIG.  2 . The position assurance latch member  36  fits immediately behind the trailing edge of the PCB  14  as shown in FIG.  5  and can only be fully inserted into the body of the connector  10  if the PCB  14  is fully inserted. The latch member  36  also prevents the PCB  14  from being backed out during use. 
   As shown in  FIG. 5 , internal ribs  38  are integrally molded into the connector body  10  to define a series of parallel channels which receive the wires  18  and also receive the crimped spring terminals  40  and  42  to engage the edge contacts  16  on the upper and lower surfaces adjacent the leading edge of the PCB  14  when it is inserted into the connector  10  in the proper orientation. This eliminates the need for lead frames in providing electrical connectivity between the power source and ground and the intelligent components on the PCB  14 . 
   Additional wire guide ribs  44  are integrally molded into the interior of the second connector  12  as best shown in FIG.  1 . These ribs  44  also provide insertion channels or guides for the wires  20  as well as means to provide for the insertion of additional crimped wire end terminals  46 . The terminals  46 , like the terminals  40  and  42 , have spring end portions to engage the edge contacts  16  on the lower surface adjacent the trailing edge of the PCB  14  as best shown in FIG.  3 . 
   Additional position assurance for the proper insertion of the PCB is provided by interior bars  48  on the inside laterally opposite surfaces of the first connector  10  in registry with the PCB guide slot provided by ribs  32  and working in combination with detent notches  49  formed in the laterally opposite edges of the PCB  14  adjacent the lead edge thereof. The bars  48  and the small detent notches  49  receive and hold the PCB  14  in the fully inserted position. Thereafter, a C-shaped molded plastic security latch  50  is inserted into the open end of the first connector with arms which project into and behind the resilient detent arms  48  so as to prevent the detent arms from flexing outwardly. This essentially locks the PCB  14  in place. Alternatively, the interior bars  48  could be designed to be more difficult to separate from the detent notches  49 , such that the bars themselves act as a more permanent lock without the help of security latch  50 . The latch  50  could then be used simply as a PCB position assurance device. 
   Cover  52  is used to protect the contact surfaces of terminals  46 . Additional latch  54  is provided to secure the crimped spring terminals of the second connector  12  in place as shown in FIG.  2 . All of the latches are shaped and sized to slide into guideways providing some friction and may have detents to provide snap-fits as desired. 
   In use, the wires  18  and  20  are attached to the terminals  40 ,  42  and  46  by crimping and the terminals are assembled into their respective connector bodies  10  and  12 . The PCB is loaded into the body  10  in the proper orientation. The latch  36  is driven into place to prevent the PCB from being removed from the connector  10 . Cover  52  and latch  54  are assembled on the connector  12  after the terminals are installed. It will only be possible to fully insert the latch if the PCB is in the correct orientation and is all the way in. The connector  12  is then inserted into the connector  10 . The components  60  on the PCB  14  are now ready to be energized by the power supply wires  20  and activate and control a device via output wires  18 . 
   While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.