Continental Automotive Systems Corporation

Motorola Corporation

Vitesco Technologies Usa, LLC

Woodhead Industries, Inc.

Donald J Zito

Tomasz L Klosowiak

David W Currier

James D Baer

Nick Hopman

Valentin M Stefaniu

Keith A Meny

Uwe Stephan

Gabriel Tirlea

Michael P Mackin

Mitul M Patel

Theodore V Lester

Russ Dalbke

Wai-Tak Ho

Andrew D Alexander

Lukasz Koczwara

Tadeusz C Szarkowski

Kevin C Loewe

Heather L Havlicsek

Leobardo Martinez Hernandez

Craig A Bezek

Peter Lechowicz

Michael R Wierec

Wayne J Wright

Vladimir Mulina

A control unit having a connection structure for connecting components of the control unit to a base plate which is cost effective, and facilitates heat transfer from a printed circuit board (PCB) to the base plate. The control unit includes circuitry mounted to a PCB, and the PCB is mounted to a base plate. The circuitry is over molded with epoxy material during manufacturing. The epoxy material flows between the PCB and the base plate, such that a layer of the epoxy is disposed between the PCB and the base plate. This layer of epoxy functions as a heat transfer layer, and a connection structure to connect the PCB to the base plate. The epoxy material transfers heat from the surface of the PCB in contact with the layer of epoxy to the surface of the base plate in contact with the layer of epoxy.

Thermal connection between printed circuit board and base plate with epoxy molded material

A control unit having a connection structure for connecting components of the control unit to a base plate which eliminates the need for separate fasteners. The control unit includes circuitry mounted to a PCB, and the PCB is pre-assembled to a base plate, to form a pre-assembly. During assembly, the PCB and the base plate are aligned when placed in a tooling device which clamps and holds the pre-assembly in place during the over molding process. The circuitry is over molded with an epoxy material, such that the epoxy material flows from a top side of the PCB to underneath the base plate, and the PCB is fixed to the base plate without the use of fasteners such as screws, or adhesive materials.

Assembly of printed circuit board with overmolded epoxy to baseplate

An electronics device includes a folded printed circuit board which is folded about at least one fold region which defines a first section and a second section. A housing has a plurality of side portions. The first section of the folded printed circuit board is secured along an outer surface of a first side portion of the plurality of side portions. The housing further includes an interior. At least one first slot is defined within the interior and disposed along or near a second side portion arranged opposite the first side portion. At least one first pin member is disposed partly within the at least one first slot and extends therefrom. A distal end portion of the at least one first pin member engages with the second section of the folded printed circuit board so as to hold the second section in position over the interior of the housing.

Positioning pins for foldable printed circuit board

An attachment structure for use with a standalone control unit. The control unit includes a threaded insert located in an enclosed cavity which allows screws to be used for grounding of an EMI/RFI board, along with creating a sealed, enclosed pocket. The attachment structure allows for grounding of the PCB to the sheet metal base plate without creating a leak path to the outside of the control unit. This ground approach encapsulates the screw to prevent the formation of a leak path.

Grounding method for baseplate sealed enclosures

An electronic controller which includes a cover connected to a base plate, a housing, and a printed circuit board disposed in the housing. The base plate includes a press-fit inspection opening or aperture, and a cover is placed on the base plate over the opening, creating a seal path between the cover and the edge of the opening in the base plate. In one embodiment, there is a sealant, such as room temperature vulcanization (RTV) or heat cured sealant, dispensed on the sheet metal base plate around the perimeter of the opening, and the sealant is cured to prevent the formation of a leak path. Prior to the curing process, the cover is held in place by a pressure sensitive adhesive (PSA), as the sealant is cured. The controller is treated to a curing process to cure the sealant between the cover and the base plate.

Press-fit contact window cover retention

A retention structure which provides both soldering and vibration stabilization of a capacitor as the capacitor is mounted to a printed circuit board (PCB) of an electronic module. An aperture is part of the PCB to stabilize and prevent the capacitor from rolling during manufacturing. Once secured to the PCB, Room Temperature Vulcanization (RTV), or similar adhesive bead, is placed onto a rigidizer or base plate (typically a casted or aluminum sheet plate). Once the capacitor is soldered in place and fixated on the PCB, the assembly is then placed onto the rigidizer such that the PCB is attached to the rigidizer using an adhesive, and the RTV bead contacts and is deformed by the capacitor, connecting the capacitor to the rigidizer to provide vibration stabilization support. The electronic module includes a cover, and optional dampening/constraint pads are attached to the cover of the electrolytic capacitor for additional vibration stabilization.

Electrolytic capacitor retention device

A lead frame assembly which allows for the connection of multiple individual fixed components in various locations, while alleviating tolerance concerns by having a flexible lead frame. The lead frame assembly includes several sub-lead frames, and a plurality of interconnects which connect each of the sub-lead frames together. The lead frame assembly also includes a plurality of segments, and each segment surrounds one of the sub-lead frames, to electrically isolate each sub-lead frame. Various components are electrically connected by incorporating stamped receptacles, or slot terminals, in the sub-lead frames. The interconnects along with plastic voids allow the various attached components to have tolerance flexibility relative to one another, as various components are attached to each of the slot terminals.

Flexible lead frame connection for electronic interconnects

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.

Single layer leadframe with integrated three-row connector

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 at least one of the plurality of connectors are disposed in the same plane as the lead frame, and another of the plurality of connectors is disposed in a different plane from the lead frame.

A safety device for hand tools includes a casing having a first clasp secured to the casing for mounting to the tool. A second clasp is mounted to a retractable cable connected to a constant tension cable reel mounted within the casing: The cable is payed out of and retracted into the bottom of the housing in its normal use position, and the second clasp is attached to a fixed support or 'lock point' located below the normal working height of the tool. In use, when the tool is held by a worker and the housing is upright, a lock plate is disengaged from a ratchet plate fixed to the retractable reel so the tool is freely moveable relative to the lock point and easily maneuvered. If the tool is dropped, the reel retracts the cable as the tool begins to fall. The device is inverted as it falls below the lock point. As the device turns over, the lock plate shifts under gravity, and the weight of the tool places the cable in tension and tries to counter-rotate the hub, thus causing the lock plate to rapidly engage the ratchet plate and lock the reel, preventing further cable pay out and securing the tool before it strikes the floor or ground.

Safety tether for hand tools

A user-friendly controller provides a special dynamic interconnect which reliably connects terminals of electronic device, such as solenoids, to a circuit board to enhance vehicle performance and help obtain a smoother more comfortable ride. The special interconnect comprises a coil spring contact. The coiled spring contact can have an enlarged head which can be soldered to a contact on the circuit board. The central portion of the spring contact provides a terminal-receiving opening to slidably receive the terminal of the electronic device. The smaller end portion of the spring contact can compressively engage and dynamically contact the terminal of the electronic device. A cover can be provided to environmentally protect and cover the circuitry and circuit board. The cover can have chambers for receiving and engaging the spring contacts.

Controller with helical spring contacts

The invention relates, in general, to electrical connector assemblies, and more particularly to plastic electrical connectors that employ metal plated plastic contacts. According to an aspect of the invention, an electrical connector is provided comprising a plastic shell having an open cavity that defines an internal surface, and an electrical connector contact that comprises a metal coated area of the internal surface.

Plated plastic connection system and method of making

A method and system for monitoring air pressure or operational status of at least one particular tire of a vehicle facilitates ready identification of a relative mounting position of the particular tire. At least one pressure indicating signal is received (,of FIG.,) and is associated with a particular tire mounted at an unknown relative position on a vehicle. Physical parameter data are obtained (,) indicating physical parameter measurements at the different tires of a vehicle. The obtained physical parameter data are evaluated (,) to identify the relative mounting position of the particular tire on the vehicle. Accordingly, an operator of the vehicle may be provided with an indication (,) that an air pressure of a particular tire is less than a proper air pressure so that peak vehicle performance and necessary maintenance may be obtained. Even if the indication informs that the pressure is normal, the operator is reassured that the tires are functioning properly.

Method and system for monitoring air pressure of tires on a vehicle

The invention relates, in general, to electrical connector assemblies, and more particularly to plastic electrical connectors that employ metal plated plastic contacts. According to an aspect of the invention, an electrical connector (,) is provided having a plastic shell (,) with an open cavity (,) that defines an internal surface (,), and an electrical connector contact (,) that includes a metal coated area (,) of the internal surface (,).

A mechanical interlock arrangement is disclosed for preventing misinstallation of a plurality of associated PC boards in the mainframe chassis of an electrical or electronic apparatus. Each PC board is mounted to a subpanel which has a mounting flange with a uniquely located key tab. This keying tab is accommodated within a selectively located slot on a member positioned traverse the front face of the mainframe chassis. The keying tab may be located along the top or bottom of the mounting flange and is made of substantially rigid material to prevent such protective keying function from being easily defeated.

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Fox River Grove, IL, United States of America

Donald J Zito