Surface mount (SMD) thermocouple connector with reverse polarity protection

Abstract

This invention provides a connector for easily and accurately connecting electronic components to a printed circuit board. The connector includes a generally C-shaped conductive element that provides connection to the positive and negative terminals of a device, depending on the connector's orientation. A connector made in this way simplifies the component's structure by allowing connection to both positive and negative terminals. Due to the shape of the connector's ends, the device can only be inserted in one manner. The connector can be made from a single sheet of conductive material, generally bent into a "C" shape, with specific joints and cutouts formed therein. The connector includes a tab for quick and automatic connection to the printed circuit board, and an element for preventing interlocking if the connector is loose or disconnected during manufacturing, plating, or storage, allowing them to be added to the board quickly, accurately, and at low cost using automated processes.

Description

Technical Field

[0001] This invention relates to thermocouple connectors for use on printed circuit boards. More specifically, this invention relates to low-profile connectors for installation in confined spaces, which in one design can be reversed as positive / negative connectors, can be mounted on the printed circuit board by pick-and-place machines, and provide reverse polarity protection (error protection) through a mistake-proof design, allowing them to be used only in one direction, and requiring devices to be connected to the circuit board to be inserted into the circuit board only in a correctly aligned manner. Background Technology

[0002] Printed circuit boards (PCBs) that need to be connected to external controls or devices are known and widely used. Devices connecting external controls or devices typically include connectors, which require an opening in the board and hard soldering the connector into place. Therefore, this connection method requires additional time to complete a one-time connection and introduces questionable problems, such as damage to the PCB due to the soldering process, and significant delays in production due to the need for precise work and skilled workers. Furthermore, existing connectors are often identical components that allow devices to be connected in such a way that they can be inserted without regard to correct polarity, and incorrect insertion can damage both the device and the PCB.

[0003] The main technologies to consider in this area are products like Omega's PCC-SMP, which are female thermocouple connectors that connect to male thermocouple connectors on a printed circuit board. These are available in both miniature (PCC-SMP) and standard (PCC-OST) sizes and are offered by many different vendors. A drawback associated with these types of conventional connectors is that they are through-hole technology, requiring users to manually solder them onto the printed circuit board (i.e., these products do not utilize surface mount technology). In high-volume applications, this can become very costly manual labor or require expensive automation equipment. Another drawback of this type of product is its poor thermal coupling to the PCB, thus requiring the use of a remote temperature sensor to achieve adequate cold junction compensation (e.g., see Omega Engineering, Inc. model: PCC-SMP-*-R). This remote temperature sensor incurs additional costs and is very difficult (and expensive) to install. In many applications, this remote temperature sensor does not provide sufficient cold junction compensation. A final drawback of this design is that it cannot be used with 3-wire resistance temperature detectors (RTDs).

[0004] Previously available PAX Instruments surface mount thermocouple (SMT) contacts showcased improvements to this type of connector and connection process. This is an open-source invention on GitHub, designed by Mr. Charles Pax and a group of online followers. The improvement lies in the fact that the connector can now be SMT mounted using standard pick-and-place machines / PCB automation. The initial design was apparently intended to support the development of PAX Instruments' T400 thermocouple data logger, but PAX also decided to sell the SMT thermocouple connector separately. PAX appears to have ceased operations in 2017, as they stopped accepting orders, shipping products, and responding to customer inquiries. Therefore, their SMT thermocouple connectors are no longer available. Furthermore, a deficiency in the PAX device has been found in the lack of reverse polarity in the design, allowing users to potentially insert the thermocouple backwards, which could damage the connected device and printed circuit board. The PAX design has also been found to be quite complex, with numerous bends, making it both difficult and expensive to manufacture. Finally, due to the multiple complex bends in the design, users may insert the mating thermocouple connector into the wrong open "slot," resulting in an unreliable connection even when the polarity is correct.

[0005] Therefore, one object of the present invention is to provide a simpler device for connecting connectors to circuit boards, thereby providing a robust and reliable connection for devices such as thermocouples; to make such connectors less kinked for a stronger connection, use less material, and be easier to install, and to allow the positive and negative connections to rotate so that devices can be interconnected, and for ease of connection and protection of the devices and printed circuit boards, connection can only be made in one direction. Furthermore, the device is preferably a single-unit connector, providing a different opening at each end, so that the positive and negative terminals can be inserted into different ends through a single connector design—by placing two connectors parallel to each other in opposite directions, a connection is created, providing access to the circuit board with the correct polarity; thus saving time and money compared to creating a device for each negative and positive terminal. With this design, any number of devices can be placed side-by-side in the desired direction to create sockets for two, three, and / or more wiring systems.

[0006] As the description proceeds, other objects and advantages of the invention will become apparent. Summary of the Invention

[0007] According to the present invention, a connector element is provided, comprising: a monolith of conductive material folded to form a generally tubular element. The generally tubular element has an elongated shaft having a first end and a second end, each end being configured such that the first end mates with a positive electrical connector and the second end mates with a negative electrical connector; the connector has a tab to allow for quick connection and easy alignment of the generally tubular element with a printed circuit board. In a preferred embodiment, the connector element is made of beryllium copper plated with nickel and is formed from a monolith of conductive material folded into a generally "C" shape.

[0008] When electronic connection is required, two of these electrical connectors are placed in a generally parallel relationship and configured with opposite axes to form a wiring socket for electrical installations. Note the tabs; the placement of the connectors creates a fault-resistant connection for polarity protection. In a preferred embodiment, the connector includes alignment tabs that are generally perpendicular to the bottom of the connector element to help secure the connector element to the printed circuit board. Furthermore, the connector includes tabs projecting from the top of the connector element, generally perpendicular to the elongated axis, to prevent two or more connecting elements from becoming entangled.

[0009] When using the apparatus of the present invention, a method for providing a connection between an electrical device and a printed circuit board includes the following steps: forming a pair of generally tubular elements from a conductive material, each generally tubular element having a long axis, the ends of the generally tubular elements being formed such that one end of each axis of the generally tubular element is formed as a pin that can mate with a positive plug, and the other end of each axis of the generally tubular element is formed as a pin that can mate with a negative plug. Each tubular element is then attached and electrically connected to the printed circuit board in a generally parallel configuration and with opposite polarities to form a receptacle connector. In this way, once configured, the electrical device can be inserted into one end of each generally tubular element and electrically connected to the printed circuit board.

[0010] The devices used in this method are preferably conductive and made of materials such as nickel-plated beryllium-copper. These devices are simply made by folding sheets of material into a roughly "C" shape. In some cases, when the device has more than two prongs, three or more devices can be used to accommodate the plug element.

[0011] To facilitate easier connection of such a device to a printed circuit board, the method uses a device that includes a connector to aid in connection within the printed circuit board, and may include a second connector that protrudes from the connector element in a generally perpendicular position to the elongated axis to prevent two or more connector elements from becoming entangled with each other.

[0012] A more detailed explanation of the invention will be provided in the following description and claims and is illustrated in the accompanying drawings. Attached Figure Description

[0013] Figure 1 This is a 3D diagram of a connector based on existing technology.

[0014] Figure 2 This is a 3D view of the second type of connector in the prior art placed on a circuit board.

[0015] Figure 3 This is an exploded 3D view of a connector placed on a circuit board using existing technology.

[0016] Figure 4 This is a front view of the connector of the present invention.

[0017] Figure 5 This is a perspective view of the connector of the present invention.

[0018] Figure 6 This is a plan view of the connector of the present invention, shown with a portion cut off to show the placement of the device therein, its proper position on the printed circuit board, and its connection to an external device.

[0019] Figure 7 This is a perspective view of the connector of the present invention positioned on a printed circuit board and connected to an external device. Detailed Implementation

[0020] While the invention may take various forms of embodiments, many currently preferred embodiments are illustrated in the accompanying drawings, which will be discussed in more detail below. It should be understood that this disclosure is to be considered as illustrative of the invention and is not intended to limit the invention to the specific embodiments illustrated. It should also be understood that the title of this section of this application (“Detailed Description”) relates to the requirements of the U.S. Patent and Trademark Office and should not be considered as limiting the subject matter disclosed herein.

[0021] Referring to the accompanying drawings, the connectors of the prior art are... Figure 1 and Figure 2 The image is displayed in 3D. It can be seen that... Figure 1 The device 10 includes a conductive folded material and is connected to a printed circuit board and forms a connection with an external device (such as a thermocouple). Once connected, it forms a device that measures temperature and provides information to the circuit board for measuring the temperature of a third product and other things, so that the device composed of the circuit board can identify them. Figure 1 Device 10 in the diagram is an identical Pax connector, shown in reverse configuration, adjacent to each other. It can be seen that the opening 2 of each connector is identical, and by design, it can accommodate pins of any size, whether different or the same width, with openings on either side, sometimes resulting in incorrect polarity when inserting the device. Pax device 10 includes a tab 4 that allows the device to be placed on a circuit board. Figure 2The device 10 includes a metal element 12 attached to a printed circuit board 14, allowing electrons to flow from anode thermocouple connector 16 to the circuit board 14 for measurement by the components constituting the circuit board 14 and display on any type of display device. For example... Figure 3 As shown, device 10 is a more complex connector still in use, comprising elongated connector elements 18 that are pushed through openings 20 in circuit board 14, allowing device 10 to be attached to circuit board 14, typically by soldering. Those skilled in the art will understand that in the prior art, such connections are achieved by drilling holes in the board, pushing the device into the board, manually soldering the device to the board, and communicating electronically with the board. Such a process requires considerable time and skilled labor to establish a proper and durable connection on the circuit board. Connector 10 is a complex component that also includes openings 22 into which external instruments, such as thermocouples, can be inserted. It can be seen that the openings 22 vary in size, thus allowing the plug to be inserted in only one manner.

[0022] Now for reference Figure 4 and Figure 5 The image shows two views of the device 30 of the present invention. Figure 4 The device 30 is shown in a front view. In a preferred embodiment, the device 30 is made of a single sheet of conductive material; in a preferred embodiment, this material is a nickel-plated beryllium and copper alloy—it has excellent conductivity, can be bent and formed into desired shapes, and is corrosion-resistant. It should be understood that many other materials, mixtures, alloys, and other material types can be used as substitutes without departing from the novel scope of the invention. Figure 5 In the perspective view of device 30, it can be seen more clearly that the final product of bending the conductive material sheet is a generally C-shaped element with a top wall 32, a bottom wall 34, and side walls 36, forming a generally C-shape. A connecting tab 38 extends from the bottom wall 34 and is generally perpendicular to it, for securing device 30 to a position on the printed circuit board for automated pick-and-place assembly using known methods by those skilled in the art. A large tab 40 is disposed on the top wall 32 and extends generally perpendicular to it; this tab 40 is used to prevent device 30 from becoming entangled with other devices 30.

[0023] like Figure 5 As shown, the device 30 clearly shows that, when viewed along the direction of the figure, the left side 42 and right side 44 of the device 30 are made of different top members 42t and 44t. It can be seen that the top member 42t includes a central curved portion 42c hanging from the top wall 32 and two end members 42e hanging from the top wall 32 at a larger angle (and as shown in the figure). Figure 4As shown, the top 34t is formed to contact the bottom wall 34. In contrast, the top member 44t is a single-piece element, similar to the central curved portion 42c. Each device 30 is made in this way to provide connectors for the positive and negative terminals of electronic instruments within a single element, as will be described in more detail below. Due to the difference between the top members 42t and 44t, when correctly assembled in pairs (or in other assemblies, including the use of three connectors in a three-wire system), a single device 30 can accommodate different pins of electronic components, similar to the prior art device 10 with element 22 (in...). Figure 3 (same as in China)

[0024] Now for reference Figure 6 and 7 This shows the device 30 used in combination on circuit board 14. Figure 6 The electronic component 50 housed within the device 30 is shown; to more clearly illustrate the shape and size of the connector pin 52, the device 30 is shown partially cut off relative to it (please compare). Figure 7 (The same structure as in the previous text) so that the relative dimensions of pin 52 can be better displayed. Figure 6 As can be seen, the width of the negative pin 52n is greater than the width of the positive pin 52p; this is the standard configuration of negative and positive pins on such components. In this way, the user of device 30 can only insert electronic component 50 into the circuit board 14 on which the device of the present invention is located in one manner (i.e., attempting to insert component 50 upside down into pins 52n and 52p will not allow it to enter device 30 due to the size of the pins and the corresponding size of the opening in device 30); this is to protect component 50 and circuit board 14 from the harmful effects of accidentally reversing either polarity. Figure 6 As shown, when with Figure 5 When viewed together, the wider pin 52n can only be inserted into the right-side component 44, which has a large opening, while the narrower pin 52p can be placed on either side, but is more suitable for placement in the left-side component 42, which has leg elements 42e to help form a tight fit for the pin 52p within the device 30 and to create an obstacle to the incorrect insertion of the wider pin 52n. In this way, the connector made of two devices 30 in opposite directions forms a socket 60 for the plug element of the component 50. It should be understood that for a single component, the device 30 can form any number of individual devices 30 with the correct number of plugs in any configuration, and can be arranged side by side as needed to accommodate the number of pins from the device. Those skilled in the art will understand that the device of the present invention covers all SMT-mountable thermocouple connectors that incorporate an asymmetrical design to ensure reverse polarity protection. It should also be understood that the device is not only applicable to thermocouples, but also to all electrical-based temperature sensors, including RTDs and thermistors.

[0025] Figure 7 The connection between electronic component 50 and the socket 60 of the present invention is shown. Pin 52p is clearly shown as being fitted into side 42, pin 52p is held securely in electrical communication by end member 42e, and pin 52n is shown as being held within the top 44t and bottom 34 of end 44, held in electronic communication; all of these form a circuit connecting component 50 to circuitry 14. Each device 30 is shown in the opposite direction to the other device 30 forming the socket 60, to show a single style of component 30, thereby simplifying the manufacturing process of such devices, requiring only one design to achieve the specified purpose of creating connection points for the circuit board.

[0026] Because only one type of device 30 is needed, manufacturing is simplified, and the process of creating printed circuit boards using these components is simplified and accelerated, with fewer errors, and better circuit boards are produced in a more fully automated manner, thereby increasing production capacity and providing cleaner, less faulty operation.

[0027] Specifically, this invention is a surface-mount thermocouple connector (PCC-SMD) with reverse polarity protection. While its primary application is in thermocouple sensors, it is not exclusive to thermocouples. The design of this invention can be used with all electrical-based temperature sensors, including resistance temperature detectors (RTDs) and thermistors. Similar to the prior and no-longer-available PAX technology, this thermocouple connector is a surface-mount device, meaning it is ready for automation in standard pick-and-place machines / PCB automation. This SMD-type thermocouple connector will save PCB manufacturers labor and costs, making it very attractive for high-volume applications. This invention offers at least three major improvements over existing connectors, including:

[0028] 1) This invention provides reverse polarity protection, making it "poka-yoke resistant." The PCC-SMD design has a specific function with mechanical blocking, so users cannot insert the mating thermocouple connector backwards or upside down. The device of this invention is asymmetrical and ensures that PCB manufacturers must install the connector in the way the PCB designer expects.

[0029] 2) The second improvement is that the device of the present invention can be made thinner in height than existing devices. The existing devices disclosed above have a height of 3.27 mm, while the device of the present invention, in a preferred embodiment, has a height of 2.36 mm at its highest point (a 28% reduction in height, with the same footprint). This is noteworthy because it allows for thinner electronics and more compact PCB packaging within the housing, which is very important in the development of the electronics industry.

[0030] 3) The third improvement is that the present invention contains only two main bends, producing a simple "C"-shaped geometry, while the existing device disclosed above has four main bends, producing an "E"-shaped geometry. Therefore, the existing device requires 55% more raw materials and more complex tooling. This makes the device of the present invention easier and more economical to manufacture.

[0031] Although illustrative embodiments of the invention have been shown and described, it should be understood that various modifications and substitutions can be made by those skilled in the art without departing from the novel spirit and scope of the invention.

Claims

1. A connector element for connection to a printed circuit board to enable the connection of individual electrical devices to the printed circuit board, the connector element comprising: A conductive material monolith is formed having an elongated axis and having a first end, a second end, and a central portion between the first end and the second end. The conductive material monolith is folded into a generally C-shaped form to form a generally tubular element. The first end is configured to insert only a positive electrical pin in an electronic connection, and the second end is configured to insert a negative electrical pin in an electronic connection. The generally tubular element further includes a connecting tab extending substantially perpendicular to the bottom wall and a tab extending from the top wall for establishing a quick attachment guide so that the surface mount temperature sensor connector element can be electronically attached to a printed circuit board using the first or second end in the pin insertion direction as needed.

2. The connector element according to claim 1, wherein the conductive material monolith is made of beryllium-copper and plated with nickel.

3. The connector element according to claim 1, wherein the conductive material monolithically forms two electrical connectors, the two electrical connectors being arranged in a generally parallel relationship and in an opposite axial configuration to form a wiring socket for an electrical device.

4. The connector element according to claim 3, wherein the arrangement of the two electrical connectors forms a mis-connection for polarity protection.

5. The connector element of claim 3, wherein the two electrical connectors are in a reverse polarity protection configuration and are electrically connected to the printed circuit board such that the negative pin of the plug cannot be inserted into the positive terminal of the generally tubular element.

6. The connector element of claim 1, wherein the conductive material monolith further comprises a tab projecting from the top of the generally tubular element, substantially perpendicular to the elongated axis, to prevent two or more tubular elements from becoming entangled with each other.

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