Patent Description:
International patent application <CIT> is directed to a surface mount coupling capacitor and a circuit board containing a surface mount coupling capacitor. The coupling capacitor includes a main body containing at least two sets of alternating dielectric layers and internal electrode layers. The coupling capacitor includes external terminals electrically connected to the internal electrode layers wherein the external terminals are formed on a top surface of the coupling capacitor and a bottom surface of the coupling capacitor opposing the top surface of the coupling capacitor.

British Patent Application <CIT> discloses a capacitor support which is designed to provide a connection between the capacitor and a printed circuit board. The printed circuit board is contained in a housing, which naturally comprises a housing base and a housing cover. The capacitor support is mounted by legs to the printed circuit board.

International patent application <CIT> discloses that the capacitor is connected to the printed circuit board. The cover of the housing has paired clips on its inner side and the clips are adapted to receive and retain the capacitor. The grip of the clips can be loosened and the cover can be removed, while the capacitor remains in the housing. The removal of the cover enables easy inspection of the electronic components inside the housing.

International patent application <CIT> discloses a solderless capacitor mount assembly including a housing having a base portion and a cover portion. The cover portion and base portion are couplable to each other so as to secure a capacitor to the housing. The assembly further includes at least one connector configured to couple the assembly to a printed circuit board, and at least one electrical contact configured to contact a respective at least one lead of the capacitor and provide an electrical connection for the capacitor.

US patent application <CIT> discloses a mounting circuit board of a multilayer ceramic capacitor. First and second internal electrodes are alternately exposed to both end surfaces of the ceramic body. The first and second external electrodes extend from both end surfaces of the ceramic body to a portion of a lower surface thereof. A printed circuit board has first and second electrode pads so that the first and second external electrodes are mounted thereon.

Chinese utility model <CIT> discloses an electrolytic capacitor mount.

Chinese utility model <CIT> relates to a specific super capacitor module group. A super capacitor module has a shell and an upper cover. The upper cover is connected to the shell, anode and cathode connection of the super capacitor module. The super capacitor module includes U shaped steel, circuit board and a plurality of super capacitors. The supercapacitor unit is fixed in on the circuit board and the circuit board is fixed in the recess of U-shaped steel.

It is an object of the present invention to provide a capacitor support for mounting in a housing for a printed circuit board, which saves space on a printed circuit board and enables a simple and precise mounting of the capacitor support.

The above object is achieved by a capacitor support for mounting in a housing for a printed circuit board which comprises the features of claim <NUM>.

According to an embodiment of the invention, a capacitor support is developed for mounting in a housing for a printed circuit board. The capacitor support is configured to be placed inside the housing. The housing comprises at least a housing base and a housing cover. The capacitor support comprises a base plate. A plurality of flexible arms is attached to or integrally formed on the base plate of the capacitor support and extends upwards from the base plate. The flexible arms are configured such that they cooperate with a capacitor to be mounted in the capacitor support, which is mounted to an inner surface of the housing cover. The capacitor is held by the capacitor support in a form and force fitting manner.

The advantage of the present invention is that a lot of space on a printed circuit board is saved, because the capacitor support of the invention is mounted inside the housing onto the inner surface of the housing cover. In other words, the capacitor is held by the inventive mounting method above the printed circuit board Furthermore, the configuration of the capacitor support according to invention, which is preferably made from a thermoplastic polymer, facilitates the mounting procedure of the capacitor support and does not cause any stress or damage to the printed circuit board.

According to the invention the base plate of the capacitor support carries a mounting structure for electrically connecting the capacitor to the printed circuit board. A possible application for the invention is the use of the capacitor support in a housing of an engine control unit (ECU) for a vehicle. The capacitor or capacitors positioned by one or more capacitor supports provide an energy reserve for the ECU.

According to an embodiment of the invention, the capacitor support has four pairs of flexible arms which cooperate with a capacitor to be mounted in the housing in a form and force fitting manner. It is noted that the number of pairs of flexible arms should not be regarded as a limitation of the invention. It is evident for a skilled person in the art that the number of pairs of flexible arms should be selected such that a secure and reliable fixation of the capacitor is guaranteed.

According to an embodiment of the invention, the base plate carries a mounting structure for electrically connecting the capacitor, positioned by the capacitor support, to the circuitry of the printed circuit board.

According an embodiment of the invention, for mounting the capacitor support, the base plate has a plurality of ears. Each ear cooperates with a corresponding crimp on the inner surface of the inner housing cover. Preferably, the ears and the crimps are distributed homogeneously around the capacitor support. This enables a homogeneous force for holding the capacitor support to the inner surfaces of the housing cover. According a further embodiment of the invention, in order to achieve a correct positioning of the capacitor support, an underside of the base plate carries a plurality of pins which fit in a poka yoke manner in corresponding holes of the housing cover.

According to a further embodiment of the invention, the underside of the base plate carries a plurality of pins, which fit in a poka yoke manner into corresponding holes of the housing cover. The pins are designed such that the pins overtop a outer surface of the housing cover. Preferably, the holes of the housing cover have a larger diameter at the outer surface of the housing cover than a diameter of the pins. The holes at the outer surface of the housing cover form a pot-like hole into which a portion of the pins is melted. Finally, the melted material of the pins is flush with the outer surface of the housing cover. Once the material (e. thermoplastic polymer) is solidified, the capacitor support is fixed to the housing cover.

According to a further embodiment of the invention, the capacitor support is injection moulded directly onto the inner surface housing base. According to a further embodiment of the invention, the housing cover has at least two positioning pins for a mould which is used to form the capacitor support and to fill a plurality of holes in the housing cover with the material of the capacitor support. Here again the material (e. thermoplastic polymer) solidifies in the holes and the capacitor support is firmly and permanently attached to the inner surface of the housing cover.

According to an additional embodiment of the invention, the base plate of the capacitor support has formed at least two holes. Through each of the at least two holes a corresponding stud reaches, which is positioned on the inner surface of the housing cover. In a further embodiment, in order to fix the capacitor support permanently to the inner surface of the housing cover, a head is formed on each stud, preferably by a cold stamping process. The head fixes the capacitor support permanently to the inner surface of the housing cover.

For carrying out another fixing method of the capacitor support to the inner surface of the housing cover, in an embodiment of the invention, the capacitor support comprises starlocks. Each starlock is pushed over the corresponding stud and is in contact with the base plate of the capacitor support and thereby fixes the capacitor support to the inner surface of the housing cover.

Preferably, each stud is made from metal.

Same reference numerals refer to same elements or elements of similar function throughout the various figures. Furthermore, only reference numerals necessary for the description of the respective figure are shown in the figures. The shown embodiments represent only examples of how the invention can be carried out. This should not be regarded as a limitation of the invention.

<FIG> shows a perspective, exploded view of an embodiment of a housing <NUM> for an electric circuitry <NUM> capabilities according to prior art. The electric circuitry <NUM> requires some energy reserve capabilities. According to the prior art embodiment shown here, the electric circuitry <NUM>, together with the housing <NUM>, is an engine control unit (ECU) for a vehicle (not shown); however, the invention is not limited to an ECU. The housing <NUM> has a housing base <NUM> and a housing cover <NUM>. The housing base <NUM>, the housing cover <NUM> and an electric connector <NUM> enclose a circuit board <NUM> and at least one capacitor <NUM>. A plurality of contact pins <NUM> are attached to the circuit board <NUM> to provide electric contact between the at least one capacitor <NUM> and the circuit board <NUM>. According to an embodiment of the invention, the housing base <NUM> can be a die cast plate; however, the invention is not limited to a die cast plate. The housing cover <NUM> can be made of plastic. In case the field of application is vehicles, the housing cover <NUM> for the electric circuitry <NUM> can be made of polybutylene terephthalate (PBT GF <NUM>), which is a <NUM>% glass fibre reinforced, medium viscous polybutylene terephthalate (PBT) with high stiffness and toughness as well as high dimensional stability and chemical resistance. However, the invention is not limited to this specific configuration of the housing cover <NUM>. Typical applications for PBT are technical and precision parts in automobile, industrial, and appliances industry.

<FIG> is a perspective view of one embodiment of a capacitor support <NUM> according to the invention. The capacitor support <NUM> comprises a base plate <NUM>. The base plate <NUM> carries a plurality of flexible arms <NUM> which are designed to cooperate and/or hold a capacitor <NUM> (see <FIG>) in a form and force fitting manner. For example, the embodiment shown here can hold a capacitor <NUM> which has a cylindrical shape, but other forms of the capacitor <NUM> and corresponding shapes of the flexible arms <NUM> are possible without leaving the scope of claims. Furthermore, the base plate <NUM> has a mounting structure <NUM> formed thereon which is used for electrically connecting the capacitor <NUM> to the printed circuit board <NUM>. Preferably, the capacitor support <NUM> is formed by an injection moulding process. The material of the capacitor support <NUM> is, for example, a thermoplastic polymer.

The embodiment of the capacitor support <NUM> as shown in <FIG> has a plurality of ears <NUM> formed at an outer edge <NUM> of the base plate <NUM>. The ears <NUM> are oriented perpendicular to the base plate <NUM>. An underside <NUM> of the base plate <NUM> carries a plurality of pins <NUM>.

<FIG> are perspective views of the mounting process of the capacitor support <NUM> (shown in <FIG>) to an inside <NUM> or an inner surface <NUM> of the housing cover <NUM>. The housing cover <NUM> has a plurality of holes <NUM> into which the pins <NUM> (see <FIG>) of the underside <NUM> of the base plate <NUM> fit. The pins <NUM> of the underside <NUM> of the base plate <NUM> and the respective holes <NUM> of the housing cover <NUM> are arranged in a poka yoke manner. Poka yoke has the advantage that the capacitor support <NUM> is positioned in the correct manner, i.e. fixed and in the desired position, to the inner surface <NUM> of the housing cover <NUM>. In order to fix the capacitor support <NUM> to the housing cover <NUM>, the housing bas cover <NUM> has a plurality of crimps <NUM> which cooperate with corresponding ears <NUM> of the base plate <NUM> of the capacitor support <NUM>. As shown in <FIG>, the capacitor support <NUM> is mounted to the inner surface <NUM> of the housing cover <NUM>. The crimps <NUM> on the inner surface 9I of the housing cover <NUM> operate with corresponding ears <NUM> of the base plate <NUM> and firmly attach the capacitor support <NUM> to the inner surface <NUM> of the housing cover <NUM>.

<FIG> show a further embodiment for mounting the capacitor support <NUM> onto the inside <NUM> of the housing cover <NUM>. <FIG> is a perspective view of a further embodiment of a capacitor support <NUM> according to the invention in relation to an embodiment of the mounting structure <NUM> (see <FIG>) of the housing cover <NUM>. The capacitor support <NUM> has a plurality of pins <NUM> formed at an underside <NUM> of the base plate <NUM>. A plurality of holes <NUM> constitute a mounting possibility of the housing cover <NUM>. The pins <NUM> at the underside <NUM> of the base plate <NUM> and the holes <NUM> in the housing cover <NUM> are arranged as well in a poka yoke manner, which allows correct positioning of the capacitor support <NUM> on the inner surface <NUM> of the housing cover <NUM>. In the embodiment described here, the underside <NUM> of the base plate <NUM> carries four pins <NUM> for positioning and mounting the capacitor support <NUM> to the inner surface of the housing cover <NUM>. It has to be noted that the number of pins <NUM> is used for describing the invention and should not be used to limit the scope of the invention. The correct positioning of the capacitor support <NUM>, as shown in <FIG>, is achieved when the underside <NUM> of the base plate <NUM> rests on the inner surface <NUM> of the housing cover <NUM>.

<FIG> shows a side view of the embodiment of capacitor support <NUM> of <FIG> which is positioned on the inner surface <NUM> of the housing cover <NUM>. The pins <NUM> of the underside <NUM> of the base plate <NUM> overtop the outer surface <NUM> of the housing cover <NUM>. In order to mount the capacitor support <NUM> permanently to the inner surface <NUM> of the housing cover <NUM>, the overtop portion of the pins <NUM> is melted for example by a welding process with a laser. <FIG> is a perspective of the outer surface <NUM> of the housing cover <NUM>. After the welding process the pins <NUM> are flush with the outer surface 9I of the housing cover <NUM>.

<FIG> is a perspective, partly cut away view of capacitor support <NUM> mounted on the inner surface <NUM> of the housing cover <NUM>. The holes <NUM> in the housing cover <NUM> have a larger diameter 8D at the outer surface 9O of the housing cover <NUM> than a diameter 18D of the pins <NUM>. The larger holes <NUM> at the outer surface 9O of the housing cover <NUM> have a pot-like form. During the welding process of a portion of the pins <NUM>, the liquefied material of the pins <NUM> fills the pot-like form. Consequently, the pins <NUM> are flush with the outer surface 9O of the housing cover <NUM>. After the hardening of the melted material of the pins <NUM>, the capacitor support <NUM> is permanently fixed to the inner surface <NUM> of the housing cover <NUM>.

<FIG> show perspective views of another embodiment of a capacitor support <NUM> mounted onto inner surface <NUM> of the housing cover <NUM> according to the invention. The capacitor support <NUM> is, for example, injection moulded directly onto the inner surface <NUM> of the housing cover <NUM>. The injection moulding process is carried out in that the mould (not shown) is positioned over the inner surface <NUM> of the housing cover <NUM>. The correct positioning of the mould is achieved by at least two positioning pins <NUM> on inner cover <NUM> of the housing cover <NUM>. As shown in <FIG>, the housing cover <NUM> has a plurality of holes <NUM>. During the injection process, the material (e. thermoplastic polymer) of the capacitor support <NUM> flows as well into the holes <NUM>, preferably four holes <NUM>, of the housing cover <NUM>. The holes <NUM> are used to keep the capacitor support <NUM> in place. At the inner surface 9I, the holes <NUM> have a form which is already described with respect to <FIG>.

<FIG> describe an additional embodiment for mounting and fixing the capacitor support <NUM> inner surface <NUM> of the housing cover <NUM> according to the invention. As shown in <FIG>, the inner surface <NUM> of the housing cover <NUM> carries a plurality of studs <NUM>. The base plate <NUM> of the capacitor support <NUM> has formed at least two holes <NUM>. The capacitor support <NUM> is positioned such that one stud <NUM> reaches through one hole <NUM> of the base plate <NUM> (see <FIG>). Preferably, the studs <NUM> are made of metal. In order to fix the capacitor support <NUM> to the inner surface <NUM> of the housing cover <NUM>, the studs <NUM> are deformed by a cold stamp process. As a result of the cold stamp process (see <FIG>) a head <NUM> is formed per each stud <NUM>. The heads <NUM> firmly attach the capacitor support <NUM> to the inner surface <NUM> of the housing cover <NUM>. Preferably, four studs <NUM> are provided on the inner surface <NUM> of the housing cover <NUM>.

<FIG> describe a modified embodiment for mounting and fixing the capacitor support <NUM> to the inner surface <NUM> of the housing cover <NUM> according to the invention. The inner surface <NUM> of the housing cover <NUM> carries as plurality of studs <NUM>. The base plate <NUM> of the capacitor support <NUM> has formed at least two holes <NUM>. The capacitor support <NUM> is positioned such that the studs <NUM> reach trough the corresponding holes <NUM> provided in the base plate <NUM> of the capacitor support <NUM>. <FIG> shows the step of firmly attaching the capacitor support <NUM> to the inner surface <NUM> of the housing cover <NUM>. A respective starlock <NUM> is placed over each of the plurality of studs <NUM>, and each starlock <NUM> is pushed on each of the studs <NUM> until the capacitor support <NUM> is attached to the inner surface <NUM> of the housing cover <NUM>. Preferably, the studs <NUM> are metal studs as mentioned above. Furthermore, three or four studs <NUM> provide the best fixing of the capacitor support <NUM> to the inner surface 9I of the housing cover <NUM>.

Claim 1:
A capacitor support (<NUM>) carrying a capacitor (<NUM>), wherein the capacitor support (<NUM>) is mounted in a housing (<NUM>) for a printed circuit board (<NUM>) inside the housing (<NUM>), which comprises at least a housing base (<NUM>) and a housing cover (<NUM>),
characterized by
a base plate (<NUM>);
a plurality of flexible arms (<NUM>) extending upwards from the base plate (<NUM>) and cooperating in a form and force fitting manner with the capacitor (<NUM>), wherein the capacitor support (<NUM>) is mounted to an inner surface (9I) of the housing cover (<NUM>) and above the printed circuit board (<NUM>); and
a mounting structure (<NUM>) formed on the base plate (<NUM>) of the capacitor support (<NUM>) for electrically connecting the capacitor (<NUM>) from the housing cover (<NUM>) above the printed circuit board (<NUM>) to the printed circuit board (<NUM>).