Electrical unit

Abstract

An electrical unit may include: a circuit board, a plurality of first terminals having respective first tabs fixed to the circuit board, a plurality of second terminals having respective second tabs fixed to the circuit board, the second tabs being offset from the first tabs in a first direction and a second direction, and / or a terminal housing disposed above the plurality of first terminals and the plurality of second terminals and connected to the circuit board. A method of assembling an electrical unit may include: connecting the first tab to the circuit board, connecting the second tab to the circuit board so that each second tab is at least partially offset from each first tab of the plurality of first terminals in the first direction and the second direction, and / or disposing the terminal housing above the first terminal and the second terminal.

Description

Technical Field

[0001] The present disclosure relates generally to electrical units, including, for example, electrical units that may be used as power distribution units and / or in conjunction with vehicles. background

[0002] The following description of this background is for the purpose of providing background content only. Therefore, no aspect of this background description is either explicitly or implicitly admitted to be prior art against the present disclosure to the extent it is not otherwise proven to be prior art.

[0003] Some circuit board designs are not space efficient, are not constructed for high currents, and / or are complex to use and assemble.

[0004] Therefore, there is a need for solutions / options that minimize or eliminate one or more challenges or disadvantages of circuit board assemblies.The foregoing discussion is intended only to illustrate examples of the art and is not an admission of scope.

[0005] Overview

[0006] In an embodiment, the electrical unit may include: a circuit board, a plurality of first terminals having corresponding first tabs fixed to the circuit board, a plurality of second terminals having corresponding second tabs fixed to the circuit board, and / or a terminal housing disposed above the plurality of first terminals and the plurality of second terminals and connected to the circuit board, the second tabs deviating from the first tabs in a first direction and a second direction.

[0007] According to an embodiment, a method for assembling an electrical unit may include: connecting first tabs of a plurality of first terminals to a circuit board, connecting second tabs of a plurality of second terminals to the circuit board so that each second tab at least partially deviates from each first tab of the plurality of first terminals in a first direction and a second direction, disposing a terminal housing above the plurality of first terminals and the plurality of second terminals, and / or connecting the terminal housing to the circuit board.

[0008] This application also provides the following:

[0009] 1) An electrical unit, comprising:

[0010] Circuit boards;

[0011] a plurality of first terminals having respective first tabs secured to the circuit board;

[0012] a plurality of second terminals having respective second tabs secured to the circuit board, the second tabs being offset from the first tabs in a first direction and a second direction; and

[0013] A terminal housing is disposed above the plurality of first terminals and the plurality of second terminals and is connected to the circuit board.

[0014] 2) The electrical unit according to 1), wherein top edges of the plurality of first terminals are disposed at a first distance from the circuit board;

[0015] The bottom edges of the plurality of second terminals are disposed at a second distance from the circuit board; and

[0016] The second distance is substantially equal to or less than the first distance.

[0017] 3) The electric unit according to 2), wherein the plurality of first terminals and the plurality of second terminals do not extend beyond the terminal housing.

[0018] 4) The electric unit according to 2), comprising an electric unit housing at least partially disposed around the circuit board and having a side wall and a connector wall.

[0019] 5) The electrical unit according to 4), comprising: a first male terminal at least partially disposed in the connector wall and a first one of the plurality of first terminals; and

[0020] A second male terminal is at least partially disposed in the connector wall and a first one of the plurality of second terminals.

[0021] 6) The electrical unit according to 5), wherein the first male terminal comprises a first male terminal first portion and a first male terminal second portion;

[0022] The second male terminal includes a second male terminal first portion and a second male terminal second portion;

[0023] The first male terminal first portion and the second male terminal first portion are offset in two offset directions; and

[0024] The first male terminal second portion and the second male terminal second portion are generally aligned in two alignment directions such that the first male terminal and the second male terminal convert the staggered configuration of the plurality of first terminals and the plurality of second terminals into a parallel configuration.

[0025] 7) The electric unit according to 5), wherein the terminal housing includes a plurality of first recesses, a plurality of second recesses, a plurality of third recesses, and a plurality of fourth recesses;

[0026] The plurality of first terminals are disposed in the plurality of first recesses;

[0027] The plurality of second terminals are disposed in the plurality of second recesses;

[0028] The first male terminal is partially disposed in one of the plurality of third recesses;

[0029] The second male terminal is partially disposed in one fourth recess of the plurality of fourth recesses; and

[0030] The plurality of third recesses and the plurality of fourth recesses are substantially perpendicular to the plurality of first recesses and the plurality of second recesses.

[0031] 8) The electrical unit according to 5), comprising: a second plurality of first terminals fixed to the circuit board;

[0032] a second terminal housing disposed over the second plurality of first terminals and connected to the circuit board; and

[0033] An additional male terminal is partially disposed in the second plurality of first terminals and the connector wall.

[0034] 9) The electric unit according to 2), wherein the terminal housing includes a plurality of first recesses, a plurality of second recesses, a plurality of third recesses, and a plurality of fourth recesses;

[0035] The plurality of third recesses and the plurality of fourth recesses are substantially perpendicular to the plurality of first recesses and the plurality of second recesses;

[0036] The plurality of third recesses intersect corresponding first recesses of the plurality of first recesses; and

[0037] The plurality of fourth recesses intersect corresponding second recesses of the plurality of second recesses.

[0038] 10) The electrical unit according to 9), wherein the plurality of first recesses comprises a first height;

[0039] The plurality of second recesses comprises a second height; and

[0040] The second height is greater than the first height.

[0041] 11) The electrical unit according to 10), wherein the plurality of third recesses are disposed at a third distance from the circuit board;

[0042] The plurality of fourth recesses are disposed at a fourth distance from the circuit board; and

[0043] The fourth distance is greater than the third distance.

[0044] 12) The electric unit according to 2), wherein a wall of the terminal housing contacts rear edges of the plurality of first terminals and the plurality of second terminals.

[0045] 13) A method for assembling the electrical unit according to 1), the method comprising:

[0046] connecting the first tabs of the plurality of first terminals to the circuit board;

[0047] connecting the second tabs of the plurality of second terminals to the circuit board so that each second tab is at least partially offset from each first tab of the plurality of first terminals in the first direction and the second direction;

[0048] disposing the terminal housing over the plurality of first terminals and the plurality of second terminals; and

[0049] The terminal housing is connected to the circuit board.

[0050] 14) The method according to 13), wherein disposing the terminal housing includes disposing the terminal housing so that an inner wall of the terminal housing contacts a rear edge of at least one of the plurality of first terminals and the plurality of second terminals.

[0051] 15) The method according to 13), comprising: inserting a plurality of third terminals into a connector portion of a connector wall; and

[0052] The connector wall is moved to insert the plurality of third terminals into the plurality of first terminals, the plurality of second terminals, and the terminal housing.

[0053] 16) The method according to 15), wherein the plurality of third terminals are arranged in a plurality of mirrored and stacked pairs.

[0054] 17) The method according to 15), wherein the front edges of the plurality of first terminals and the plurality of second terminals are substantially aligned with the edge of the circuit board;

[0055] The front wall of the terminal housing is substantially aligned with the edge of the circuit board;

[0056] A side wall of the electric unit housing of the electric unit is disposed adjacent to the front wall of the terminal housing and the edge of the circuit board; and

[0057] The connector wall is disposed adjacent to the side wall.

[0058] 18) The method according to 15), wherein the plurality of first terminals include first female terminals;

[0059] The plurality of second terminals include a second female terminal;

[0060] The plurality of third terminals include a first male terminal and a second male terminal;

[0061] The first male terminal comprises a first male terminal first portion and a first male terminal second portion offset from the first male terminal first portion;

[0062] The second male terminal comprises a second male terminal first portion and a second male terminal second portion offset from the second male terminal first portion;

[0063] After moving the connector wall, the first male terminal first portion is at least partially disposed in the first female terminal, and the second male terminal first portion is at least partially disposed in the second female terminal; and

[0064] The first male terminal second portion and the second male terminal second portion are offset in an offset direction and are substantially aligned in two alignment directions.

[0065] 19) The method according to 18), wherein the circuit board is substantially parallel to the XY plane and substantially perpendicular to the Z direction; and

[0066] The offset direction is the Z direction, and the two alignment directions are the X direction and the Y direction.

[0067] 20) The method according to 18), comprising: providing a plurality of fourth terminals;

[0068] fixing the tabs of the plurality of fourth terminals to the circuit board;

[0069] disposing a second terminal housing above the plurality of fourth terminals;

[0070] connecting the second terminal housing to the circuit board; and

[0071] inserting a rear portion of the fifth terminal into the second connector portion of the connector wall;

[0072] Wherein, moving the connector wall includes inserting a front portion of the fifth terminal into the plurality of fourth terminals and the second terminal housing.

[0073] The foregoing and other possible aspects, features, details, utilities and / or advantages of examples / embodiments of the present disclosure will be apparent by reading the following description and by examining the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0074] Although the claims are not limited to specific illustrations, an understanding of the various aspects may be gained through a discussion of various examples. The drawings are not necessarily to scale, and certain features may be exaggerated or hidden to better illustrate and explain the innovative aspects of the examples. In addition, the exemplary illustrations described herein are not exhaustive or otherwise limiting, and are not limited to the precise forms and configurations shown in the drawings or disclosed in the following detailed description. The exemplary illustrations are described in detail with reference to the following drawings:

[0075] Figure 1 is an exploded perspective view generally illustrating an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0076] Figure 2 is an exploded perspective view generally illustrating an embodiment of a terminal housing and a terminal in accordance with the teachings of the present disclosure.

[0077] Figure 3 is a side view generally illustrating an embodiment of a terminal housing, circuit board, and terminal in accordance with the teachings of the present disclosure.

[0078] Figure 4A and Figure 4B is a cross-sectional view generally illustrating an embodiment of a terminal housing, a circuit board, and a terminal in accordance with the teachings of the present disclosure.

[0079] Figure 5A , Figure 5B and Figure 5C is a side view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0080] Figure 6 is a top view generally illustrating an embodiment of a circuit board in accordance with the teachings of the present disclosure.

[0081] Figure 7 is a perspective view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0082] Figure 8-10 is a perspective view generally illustrating a portion of an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0083] Fig.11 is a cross-sectional view generally illustrating an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0084] Fig.12 is an exploded perspective view generally illustrating an embodiment of a terminal housing and a terminal in accordance with the teachings of the present disclosure.

[0085] Fig.13 is a side view generally illustrating an embodiment of a terminal housing, circuit board, and terminal in accordance with the teachings of the present disclosure.

[0086] Fig.14A and Fig. 14B is a side view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0087] Fig.15 is a perspective view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0088] Fig.16 and Fig.17 is a perspective view generally illustrating a portion of an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0089] Fig.18 is an exploded perspective view generally illustrating an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0090] Fig.19 is an exploded perspective view generally illustrating an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0091] Fig. 20 is a perspective view generally illustrating an embodiment of a connector portion in accordance with the teachings of the present disclosure.

[0092] Fig.21 is a perspective view generally illustrating an embodiment of a terminal housing, a circuit board, and a terminal according to the teachings of the present disclosure.

[0093] Fig. 22 is a perspective view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0094] Fig.23 is a cross-sectional view generally illustrating a portion of an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0095] Fig.24 and Fig.25 is a perspective view generally illustrating an embodiment of a terminal in accordance with the teachings of the present disclosure.

[0096] Fig.26 is a top view generally illustrating an embodiment of a connector portion in accordance with the teachings of the present disclosure.

[0097] Fig. 27 is a cross-sectional view generally illustrating a portion of an embodiment of an electrical unit in accordance with the teachings of the present disclosure.

[0098] Fig.28 is a perspective view generally illustrating an embodiment of a terminal housing and a circuit board in accordance with the teachings of the present disclosure.

[0099] Fig.29 is a bottom view generally illustrating an embodiment of a circuit board in accordance with the teachings of the present disclosure.

[0100] Fig.30 is a top view generally illustrating an embodiment of a circuit board and terminals in accordance with the teachings of the present disclosure.

[0101] Fig.31 is a perspective view generally illustrating an embodiment of a connector portion in accordance with the teachings of the present disclosure.

[0102] Fig.32 is a perspective view generally illustrating an embodiment of a terminal housing, a circuit board, and a terminal according to the teachings of the present disclosure. Detailed Description

[0103] Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. Although the present disclosure will be described in conjunction with embodiments and / or examples, they do not limit the present disclosure to these embodiments and / or examples. On the contrary, the present disclosure covers alternatives, modifications and equivalents.

[0104] In an embodiment, such as in Figure 1 , the electrical unit 20 may include an electrical unit housing 22 and / or a circuit board 24, which may be at least partially disposed in the electrical unit housing 22. The electrical unit housing 22 may include a side wall 30, a lower cover 32, an upper cover 34, and / or a connector wall 36. The side wall 30 may include a first portion 30A, a second portion 30B, a third portion 30C, and / or a fourth portion 30D, which may be disposed in a rectangular configuration and may extend between the lower cover 32 and the upper cover 34 to provide an interior space 38, in which the circuit board 24 may be at least partially disposed. The connector wall 36 may be disposed adjacent to and / or connected to the first portion 30A of the side wall 30.

[0105] According to an embodiment, one or more electrical components 50 may be connected to the circuit board 24. The one or more electrical components 50 may include, for example, but not limited to, relays, controllers, fuses, capacitors, resistors and / or inductors, etc. The circuit board 24 may be, for example, substantially parallel to the XY plane and / or substantially perpendicular to the Z direction (e.g., vertical direction). The first terminal housing 76 and / or the second terminal housing 78 may be connected to the circuit board 24, such as at or around the edge 24A of the circuit board 24.

[0106] In an embodiment, the electrical unit 20 may be configured to connect to one or more external electrical connectors, such as a first external connector 52 and / or a second external connector 54. The connector wall 36 may include a first connector portion 56 configured to connect to the first external connector 52 and / or may include a second connector portion 58 configured to connect to the second external connector 54. The connector wall 36 may be disposed substantially perpendicular to the circuit board 24 and / or substantially parallel to the YZ plane. The electrical unit 20 may include a plurality of terminals configured to provide electrical connections between the external connectors 52, 54 and the circuit board 24 and / or the electrical components 50 connected thereto. For example, but not limited to, the electrical unit 20 may include a plurality of first terminals 70 (e.g., first terminals 70 1-5 ), a plurality of second terminals 72 (eg, second terminals 72 1-5 ) and / or a plurality of third terminals 74 (eg, third terminals 74 1-10 ), some or all of these terminals may be at least partially disposed in the first terminal housing 76 (see, e.g. Figure 2 The first terminal housing 76 may be disposed at or around the edge 24A of the circuit board 24 .

[0107] According to an embodiment, such as in Figure 2 , Figure 3 , Figure 4A , Figure 4B , Figure 5A and Figure 5B As generally shown in FIG. 1 , the first terminal 70 may include an L-shaped configuration having a tab 90 extending generally downward (e.g., in the Z direction) for connection with the circuit board 24 and a mating portion 92 for mating with the corresponding third terminal 74. The mating portion 92 may include a pair of prongs 94, which may extend generally perpendicular to the tab 90, such as extending in the X direction (e.g., the first terminal 70 may be configured as a female terminal). The second terminal 72 may include a tab 100 extending generally downward for connection with the circuit board 24 and a mating portion 102 for mating with the corresponding third terminal 74. The mating portion 102 may include a pair of prongs 104, which may extend generally perpendicular to the tab 100, such as extending in the X direction (e.g., the second terminal 72 may be configured as a female terminal). The second terminal 72 may include a neck 106 disposed between the tab 100 and the prongs 104. The neck 106 may extend generally upward. The neck may include a narrow portion 108 (eg, having a reduced X dimension) that may facilitate deflection of the second terminal 72 (eg, in one or both X directions), such as when / during connection with the third terminal 74 .

[0108] In an embodiment, the first terminal 70 and the second terminal 72 may include contact portions 120A, 120B, 122A, 122B, and the contact portions 120A, 120B, 122A, 122B may be configured to contact the circuit board 24 and / or limit the depth of insertion of the terminals 70, 72 into the circuit board 24. The first contact portions 120A, 122A of the first and second terminals 70, 72 may be similar or substantially the same in shape / size. The second contact portions 120B, 122B of the terminals 70, 72 may include different shapes / sizes. For example, but not limited to, such as if the tab 100 of the second terminal 72 is connected to the hole 142 that is closer to the edge 24A of the circuit board 24 than the hole 140 (the tab 90 of the first terminal 70 may be connected to the hole 140), the second terminal 72 may include a second contact portion 122B that includes a larger X dimension than the second contact portion 120B of the first terminal 70 (see, for example Figure 4A , Figure 4B and Figure 6 ). A larger X dimension can facilitate arranging the terminals in a staggered configuration while also arranging the rear edges 124, 126 of the terminals 70, 72 adjacent to and / or contacting the rear wall 76A of the terminal housing 76. If the tab 90 of the first terminal 70 is connected closer to the edge 24A of the circuit board 24 than the tab 100 of the second terminal 72 (e.g., if the hole 140 is closer to the edge 24A than the hole 142), the second contact portion 120B of the first terminal 70 can have a larger X dimension than the second contact portion 122B of the second terminal 72.

[0109] In an embodiment, the first terminal 70 and / or the second terminal 72 can be substantially planar. For example, but not limited to, when connected to the circuit board 24, the first terminal 70 and the second terminal 72 can be substantially parallel to each other and / or parallel to the XZ plane.

[0110] According to an embodiment, such as in Figure 2-5B, the second terminal 72 can be taller than the first terminal 70. For example, but not limited to, when connected to the circuit board 24, the top edge 128 of the first terminal 70 can be disposed at a distance D1 from the circuit board 24 (e.g., in the Z direction), and the top edge 130 of the second terminal 72 can be disposed at a distance D2 from the circuit board 24, and the distance D2 can be greater than the first distance D1. In some configurations, the bottom edge 132 of the mating portion 102 / prong 104 of the second terminal 72 can be disposed at a distance D3 from the circuit board 24, and the distance D3 can be similar to or equal to the distance D1 (e.g., the top edge 128 of the first terminal 70 can be disposed at substantially the same height as the bottom edge 132 of the second terminal 72). This configuration can reduce the overall height of the first terminal housing 76. For example, if the first terminal 70 and the second terminal 72 are in a stacked configuration, wherein the second terminal 72 is directly above the first terminal 70 in the Z direction, the bottom edge 132 of the second terminal 72 may need to be raised to a greater distance / height (e.g., greater than D1 / D3) to provide a minimum gap from the first terminal 70, which may also raise the top edge 130 of the second terminal 72 and increase the height of the terminal housing 76, which may be undesirable and / or impractical for at least some configurations. For example, the terminals 52A of the electrical connector 52 may be arranged close enough that it is not possible to vertically stack the terminals 70, 72 while maintaining an appropriate spacing distance.

[0111] According to an embodiment, such as in Figure 3 , Figure 6 , Figure 7 and Fig.10As generally shown in , the first terminal 70 and the second terminal 72 can be arranged in an alternating and / or staggered configuration. For example, but not limited to, the second terminal 72 can be at least partially arranged between the first terminal pair 70 (e.g., in the Y direction), so that the terminals 70, 72 are arranged in an alternating configuration of first-second-first-second. Additionally or alternatively, the tab 100 of the second terminal 72 can be connected to the circuit board 24, closer to the edge 24A of the circuit board 24 than the tab 90 of the first terminal 70, which can provide a staggered configuration. For example, but not limited to, the first terminal 70 can be inserted and / or welded in the first hole 140 of the circuit board 24, and the second terminal 72 can be inserted and / or welded in the second hole 142 of the circuit board 24, and the second hole 142 can be arranged to be closer to the edge 24A than the first hole 140 (e.g., in the X direction). Utilizing an alternating and staggered configuration, the tabs 90, 100 of the first and second terminals 70, 72 may be offset in a first direction (e.g., X direction) and a second direction (e.g., Y direction), and / or the prongs 94, 104 of the first and second terminals 70, 72 may be offset in a second direction (e.g., Y direction) and a third direction (e.g., Z direction), which may provide a minimal gap between the tabs 90, 100 and the prongs 94, 104 while minimizing the overall height and / or footprint of the terminals 70, 72 and the first terminal housing 76 on the circuit board 24 (e.g., by allowing close spacing, maintaining pad size, etc.). In some cases, the second terminals 72 may be offset from the first terminals 70 such that one or more of the second terminals 72 are aligned with a corresponding Y-direction gap between adjacent first terminals 70, even if the second terminals 72 are not directly between the first terminals 70.

[0112] According to an embodiment, such as in Figure 5C and Figure 7-10As generally shown in , the third terminal 74 may include, for example, a stepped and / or planar configuration. For example, but not limited to, the third terminal 74 may be substantially planar and may be arranged to be substantially parallel to the XY plane and / or the circuit board 24, such as when connected to the terminals 70, 72. Additionally or alternatively, the third terminal 74 may include a first portion 150 and a second portion 152, and the second portion 152 may be offset from the first portion 150, such as in the Y direction, which may provide a stepped configuration. The first portion 150 may be configured to extend into the prongs 94, 104 of the first and second terminals 70, 72, and / or the second portion 152 may be configured to extend into and / or at least partially through the first connector portion 56 of the connector wall 36 (e.g., the third terminal 74 may be configured as a male terminal). For example, the stepped configuration of the third terminal 74 may be configured to convert the staggered layout of the first and second terminals 70, 72 into a parallel layout for connection with the external electrical connector 52. The second portions 152 may be arranged, for example, in parallel rows and parallel columns.

[0113] According to an embodiment, such as in Figure 3 As generally shown in FIG. 1 , the first terminal housing 76 may include one or more recesses, such as a plurality of first recesses 160, a plurality of second recesses 162, a plurality of third recesses 164, and / or a plurality of fourth recesses 166. The plurality of first recesses 160 may be configured to at least partially receive the plurality of first terminals 70. For example, but not limited to, the plurality of first recesses 160 may include a first recess 160 aligned with each first terminal 70, and / or may extend upward from the bottom of the first terminal housing 76, generally parallel to the first terminal 70 and / or the XZ plane. When connected to the circuit board 24, the height of the first recess 160 (e.g., in the Z direction) may be at least as great as the height of the first terminal 70 above the circuit board 24. The plurality of second recesses 162 may include a second recess 162 aligned with each second terminal 72, and / or may extend upward from the bottom of the first terminal housing 76, generally parallel to the second terminal 72 and / or the XZ plane. When connected to the circuit board 24, the height of the second recess 162 (e.g., in the Z direction) can be at least as great as the height of the second terminal 72 above the circuit board 24. For example, but not limited to, the first recess 70 and the second recess 72 can be generally parallel to each other and / or can be arranged in an alternating configuration, which can correspond to the alternating configuration of the first and second terminals 70, 72. The second recess 162 can be taller than the first recess 160. The recesses 160, 162 can be configured to facilitate the correct positioning of the terminals 70, 72 for connection with the third terminal 74 (and the correct positioning before the connection).

[0114] In an embodiment, the plurality of third recesses 164 may include a third recess 164 for each third terminal 74 connected to the first terminal 70 (eg, a third recess 164 for each third terminal 74). 1-5 ). The third recess 164 can extend substantially parallel to the circuit board 24 and / or the XY plane. The third recess 164 can intersect with the corresponding first recess 160 (e.g., vertically) and / or can be aligned with the middle of the prong 94 of the first terminal 70 and / or around the middle of the first recess 160 (e.g., in the Z direction). The plurality of fourth recesses 166 can include a fourth recess 166 for each third terminal 74 connected to the second terminal 72 (e.g., for each third terminal 74 6-10 ). The fourth recess 166 can extend generally parallel to the circuit board 24 and / or the XY plane. The fourth recess 176 can intersect with the corresponding second recess 162 (e.g., vertically) and / or can be aligned with the middle of the prong 104 of the second terminal 72 (e.g., in the Z direction). The third recess 164 can be disposed at a distance D4 from the circuit board 24, and the fourth recess 166 can be disposed at a distance D5 from the circuit board 24, and the distance D5 can be greater than the distance D4. The third recess 164 and / or the fourth recess 166 can be tapered or chamfered, such as to facilitate the insertion of the third terminal 74 into the first terminal 70 and the second terminal 72, respectively, and / or into the first terminal housing 76. The recesses 164, 166 can be configured to facilitate the correct insertion of the third terminal 74 into the terminals 70, 72, which can facilitate the correct electrical connection between the third terminal 74 and the terminals 70, 72.

[0115] According to an embodiment, the first terminal 70 and the second terminal 72 can be inserted into the holes 140, 142 of the circuit board 24 (e.g., inserted in the Z direction) and can be fixed therein, such as by welding and / or press-fit connection. The first terminal housing 76 can be disposed above the first and second terminals 70, 72 (e.g., viewed from the Z direction), such as until the housing tabs 170A, 170B are inserted and / or snapped into the third hole 144 of the circuit board 24, which can connect the first terminal housing 76 to the circuit board 24. The side wall 30 can be at least partially disposed around the circuit board 24, such as after the first terminal housing 76 is connected to the circuit board 24. The side wall 30 can be configured so that the first side wall hole 180 of the first portion 30A is at least partially aligned with the first terminal housing 76, and / or so that the second side wall hole 182 of the first portion 30A is at least partially aligned with the second terminal housing 78 (see, e.g., Figure 8 The third terminal 74 may be inserted through the first sidewall aperture 180 , such as into corresponding third and fourth recesses 164 , 166 of the first and second terminals 70 , 72 and / or the first terminal housing 76 .

[0116] In an embodiment, such as in Fig. 9 and Fig.10 , the connector wall 36 can then be moved proximate the first portion 30A of the side wall 30 so that the third terminal 74 is inserted into the terminal hole 184 of the inner wall 186 of the first connector portion 56. The third terminal 74 can extend through the inner wall 186 for connection with the connector terminal 52A of the first connector 52 (see, e.g. Fig.11 ).

[0117] In some configurations, the third terminal 74 can be inserted (e.g., pressed, molded, fixed, etc.) into the terminal aperture 184 of the inner wall 186 of the first connector portion 56 before the third terminal 74 is inserted into the corresponding third and fourth recesses 164, 166 of the first and second terminals 70, 72 and / or the first terminal housing 76. Then, moving the connector wall 36 proximate the first portion 30A of the side wall 30 can include inserting the third terminal 74 into the corresponding third and fourth recesses 164, 166 of the first and second terminals 70, 72 and / or the first terminal housing 76, which can be a process of at least partially blind connection. Inserting the third terminal 74 into the terminal aperture 184 before inserting into the first and second terminals 70, 72 can facilitate proper alignment of the third terminal 74 for connection with the terminal 52A of the electrical connector 52. Additionally or alternatively, inserting the third terminal 74 into the first and second terminals 70, 72 prior to connecting the third terminal to the connector wall 36 can include increasing the size of the hole 184, which can (i) allow movement of the third terminal 74, (ii) create additional tolerance, and / or (iii) create an area for additional fluid sealing.

[0118] Reference again Figure 7-9In an embodiment, a first terminal 741 of the third terminals 74 may be inserted into a first terminal 701 of the first terminal 70, and a second terminal 742 of the third terminal 74 may be inserted into a first terminal 721 of the second terminal 72. A first portion 1501 of the third terminal 741 may be inserted into the first terminal 701 and may be offset from a first portion 1502 of the third terminal 742 in two directions (such as the Y direction and the Z direction). A second portion 1521 of the third terminal 741 and a second portion 1522 of the third terminal 742 may be offset from each other in one direction, such as in the Z direction, and / or may be substantially aligned with each other in the X direction and the Y direction, which may result in the second portion 1522 of the third terminal 742 being substantially disposed directly above the second portion 1521 of the third terminal 741 (e.g., the third terminals 741, 742 may be disposed in a stacked and mirrored configuration). The electrical unit 20 may include multiple pairs of mirrored and stacked third terminals 74 , each pair of third terminals 74 being connectable with a corresponding pair of first and second terminals 70 , 72 .

[0119] In an embodiment, such as in Fig.12 and Fig.13 , the electrical unit 20 may include one or more fourth terminals 190 that may be connected to the circuit board 24, and / or a fifth terminal 192 that may be connected to the one or more fourth terminals 190. The fourth terminal 190 may include, for example, the same or similar configuration as the first terminal 70, and may include a tab 200 and / or a mating portion 202, the mating portion 202 may include a prong 204. The tab 200 may be inserted into and / or soldered in a fourth hole 210 of the circuit board 24. The prong 204 may extend toward an edge 24A of the circuit board 24 that is generally parallel to the XZ plane. The fourth terminal 190 may be generally planar, and may be spaced from each other by, for example, about 4 mm to about 5 mm, such as about 4.5 mm. The fourth terminal 190 may be spaced farther apart than the first and second terminals 70, 72 because a higher current may be provided to the fifth terminal 192 than to the third terminal 74. For example, the fifth terminal 192 can be configured as a power terminal (e.g., for supplying power to the electrical unit 20), and the third terminal 74 can be configured as a data terminal. The fourth terminals 190 can be aligned with each other in a row / column so as to at least partially receive the fifth terminal 192. A plurality of fourth terminals 190 can, for example, be connected to the same fifth terminal 192 to distribute a relatively high current from the fifth terminal 192.

[0120] According to an embodiment, the second terminal housing 78 may include one or more first recesses 212, such as for each fourth terminal 190. The first recess 212 may be configured, for example, but not limited to, in the same or similar manner as the first recess 160 of the first terminal housing 76. For example, the first recess 212 may extend upward from the bottom of the second terminal housing 78, such as extending generally parallel to the XZ plane. The second terminal housing 78 may include one or more second recesses 214, such as for each fourth terminal 190. The second recess 214 may, for example, but not limited to, include a configuration that is the same or similar to the third recess 164 of the first terminal housing 76. For example, the second recess 214 may be generally parallel to the XY plane and / or may be generally aligned with the middle of the prong 204 (e.g., aligned in the Z direction). The second terminal housing 78 may be disposed above the fourth terminal 190, such as until one or more housing tabs 172A, 172B snap into the circuit board 24.

[0121] In an embodiment, such as in Fig.14A and 14B As generally shown in the figure, the fifth terminal 192 may include a first portion 220, a second portion 222 and / or a third portion 224, which may be arranged, for example, in a stepped and / or generally S-shaped configuration. The first portion 220 may be generally parallel to the third portion 224. The second portion 222 may be generally perpendicular to the first portion 220 and / or the third portion 224. The second portion 222 may connect the first portion 220 to the third portion 224. The first portion 220 may include a portion 226 with increased thickness, which may be configured to be used with a mating terminal configured for high current. The third portion 224 may include a plurality of protrusions 228, such as a first protrusion 228A, a second protrusion 228B and / or a third protrusion 228C, which may be configured to be inserted into and / or connected to the fourth terminal 190. For example, but not limited to, in a configuration such as Fig.15 and Fig.16 , the protrusion 228 can be substantially parallel to the XY plane (e.g., substantially perpendicular to the fourth terminal 190) and can be inserted into the corresponding prong 204, such as to electrically connect the fifth terminal 192 with the fourth terminal 190 and / or the circuit board 24. In some cases, the first portion 220 of the fifth terminal 192 can be at least partially coplanar with the circuit board 24 (see, e.g., Figure 8 ).

[0122] In an embodiment, the fifth terminal 192 can be inserted into one or more fourth terminals 190 and / or the second terminal housing 78, and then the connector wall 36 can be moved proximate to the first portion 30A of the side wall 30 so that the fifth terminal 192 is inserted into the terminal hole or hole 194 of the inner wall 196 of the second connector portion 58. The fifth terminal 192 can extend through the inner wall 196 for connection with the connector terminal 54A of the second connector 54. For example, but not limited to, moving the connector wall 36 proximate to the first portion 30A of the side wall 30 can include inserting the third terminal 74 into the first connector portion 56, and can include inserting the fifth terminal 192 into the second connector portion 58 (e.g., substantially simultaneously).

[0123] In some configurations, the fifth terminal 192 can be inserted into the terminal hole or hole 194 of the inner wall 196 of the second connector portion 58 before being inserted into the corresponding recess 214 of the fourth terminal 190 and / or the second terminal housing 78. Then, moving the first portion 30A of the connector wall 36 proximate the side wall 30 can include inserting the fifth terminal 192 into the corresponding second recess 214 of the fourth terminal 190 and / or the second terminal housing 78, which can be a process of at least partially blind connection. For example, but not limited to, moving the first portion 30A of the connector wall 36 proximate the side wall 30 can include inserting the third terminal 74 into the first and second terminals 70, 72, and can include inserting the fifth terminal 192 into the fourth terminal 190 (e.g., substantially simultaneously).

[0124] In an embodiment, the second recess 214 may be tapered or chamfered, such as to facilitate insertion of the fifth terminal 192 into the fourth terminal 190 and / or the second terminal housing 78 .

[0125] According to an embodiment, such as in Fig.17 As generally shown in FIG. 1 , in the assembled configuration, one or more third terminals 74 can extend from the connector wall 36 , such as at least partially in the first connection portion 56 , and / or the fifth terminal 192 can extend from the connector wall 36 , such as at least partially in the second connection portion 58 .

[0126] In an embodiment, such as in Fig.18, the electrical unit 320 may include an electrical unit housing 322 and / or a circuit board 324, which may be at least partially disposed in the electrical unit housing 322. The electrical unit housing 322 may include a side wall 330, a lower cover 332, and / or an upper cover 334. The side wall 330 may include a first portion 330A, a second portion 330B, a third portion 330C, and / or a fourth portion 330D, which may be disposed in a rectangular configuration and may extend between the lower cover 332 and the upper cover 334 to provide an interior space 338, in which the circuit board 324 may be at least partially disposed. In an embodiment, the lower cover 332 and / or the upper cover 334 may be integrally formed with one or more portions of the side wall 330. The lower cover 332 and / or the upper cover 334 may, for example, be substantially parallel to the XY plane and / or the circuit board 324, and / or may be substantially perpendicular to the Z direction. Upper cover 334 may include, for example but not limited to, an electrically insulating material such as plastic / polymer, and may be connected (e.g., bonded) to sidewall 330, such as in a fluid-tight manner. Sidewall 330 and lower cover 332, which may be integrally formed, may include a thermally conductive material, such as aluminum, which may facilitate heat dissipation.

[0127] According to an embodiment, one or more electrical components 350 may be connected to the circuit board 324. The one or more electrical components 350 may include, for example but not limited to, relays, controllers, fuses, capacitors, resistors and / or inductors, etc. The circuit board 324 may, for example, be substantially parallel to the XY plane and / or substantially perpendicular to the Z direction. The first terminal housing 376 and / or the second terminal housing 378 may be (e.g., mechanically) connected to the circuit board 324.

[0128] In an embodiment, the electrical unit 320 may be configured to connect to one or more external electrical connectors, such as a first external connector 352 and / or a second external connector 354. The upper cover 334 (or the lower cover 332) may include a first connector portion 356 configured to connect to the first external connector 352 and / or may include a second connector portion 358 configured to connect to the second external connector 354. The upper cover 334 may, for example, be configured as, used as, include and / or be referred to as a connector wall. The electrical unit 320 may include a plurality of terminals configured to provide electrical connections between the external connectors 352, 354 and the circuit board 324 and / or the electrical components 350 connected thereto. For example, but not limited to, the electrical unit 320 may include a plurality of first terminals 370 (e.g., first terminals 370 1-5 ), a plurality of second terminals 372 (eg, second terminals 372 1-5 ) and / or a plurality of third terminals 374 (eg, third terminals 374 1-10), some or all of which may be at least partially disposed in the first terminal housing 376 (see, e.g. Fig.19 ).

[0129] According to an embodiment, such as in Fig.19 , Fig. 22 , Fig.25 and Fig. 27 As generally shown in FIG. 1 , the first terminal 370 may include a tab 390 that extends generally downward (e.g., in the Z direction) for connection with the circuit board 324 and a mating portion 392 that extends generally upward for mating with a corresponding third terminal 374. The mating portion 392 may include a pair of prongs 394 that may extend generally parallel to the tab 390, such as extending in the Z direction (e.g., the first terminal 370 may be configured as a female terminal). The second terminal 372 may include the same or similar configuration as the first terminal 370. For example, the second terminal 372 may include a tab 400 that extends generally downward for connection with the circuit board 324 and a mating portion 402 for mating with a corresponding third terminal 374. The mating portion 402 may include a pair of prongs 404 that may extend generally parallel to the tab 400, such as extending in the Z direction (e.g., the second terminal 372 may be configured as a female terminal).

[0130] In an embodiment, the first terminal 370 and the second terminal 372 may include contact portions 420A, 420B, 422A, 422B, which may be configured to contact the circuit board 324 and / or limit the depth of insertion of the terminals 370 , 372 into the circuit board 324 .

[0131] In an embodiment, the first terminal 370 and / or the second terminal 372 can be substantially planar. For example, but not limited to, when connected to the circuit board 324, the first terminal 370 and the second terminal 372 can be substantially parallel to each other and / or parallel to the YZ plane.

[0132] According to an embodiment, such as in Fig.19 , Fig.21 , Fig. 22 , Fig.29 and Fig.30As generally shown in FIG. 3 , the first terminal 370 and the second terminal 372 can be arranged in an alternating and / or staggered configuration. For example, but not limited to, the second terminal 372 can be at least partially arranged between the first terminal pair 370 (e.g., in the Y direction), so that the terminals 370, 372 are arranged in a first-second-first-second alternating configuration. With the alternating and staggered configuration, the tabs 390, 400 of the first and second terminals 370, 372 can be offset in a first direction (e.g., X direction) and a second direction (e.g., Y direction), which can provide a minimum gap between the tabs 390, 400 and the forks 394, 404, while minimizing the total occupied space of the terminals 370, 372 and the first terminal housing 376 on the circuit board 324. One or more first terminals 370 can be aligned with the gap between the second terminals 372, and / or one or more second terminals 374 can be aligned with the gap between the first terminals 370.

[0133] According to an embodiment, such as in Fig.19 , Fig.21 , Fig. 22 , Fig.23 and Fig.24 As generally shown in , the third terminal 374 may include, for example, a step and / or planar configuration. For example, but not limited to, the third terminal 374 may be substantially planar, and may be arranged to be substantially parallel to the XZ plane and / or the circuit board 324, such as when connected to the terminals 370, 372. Additionally or alternatively, the third terminal 374 may include a first portion 450 and a second portion 452, and the second portion 452 may be offset from the first portion 450, such as offset in the X direction, which may provide a step configuration. The first portion 450 may be configured to extend into the fork 394, 404 of the first and second terminals 370, 372, and / or the second portion 452 may be configured to extend into and / or at least partially pass through the first connector portion 356 (e.g., the third terminal 374 may be configured as a male terminal). For example, the step-type configuration of the third terminal 374 may be configured to convert the staggered layout of the first and second terminals 370, 372 into a parallel layout for connection with the external electrical connector 352. The one or more third terminals 374 may be substantially perpendicular to the first terminals 370 and the second terminals 372 .

[0134] According to an embodiment, such as in Fig.28As generally shown in FIG. 3 , the first terminal housing 376 may include one or more recesses, such as a plurality of first recesses 460, a plurality of second recesses 462, a plurality of third recesses 464, and / or a plurality of fourth recesses 466. The plurality of first recesses 460 may be configured to at least partially receive the plurality of first terminals 370. For example, but not limited to, the plurality of first recesses 460 may include a first recess 460 aligned with each first terminal 370 and / or may extend generally parallel to the first terminal 370 and / or the YZ plane. The plurality of second recesses 462 may include a second recess 462 aligned with each second terminal 372 and / or may extend upward from the bottom of the first terminal housing 376, generally parallel to the second terminal 372 and / or the YZ plane. The first recesses 460 and the second recesses 462 may be substantially parallel to each other, and / or may be arranged in an alternating configuration, which may correspond to the alternating configuration of the first and second terminals 370, 372.

[0135] In an embodiment, the plurality of third recesses 464 may include a third recess 464 for each third terminal 374 connected to the first terminal 370 (eg, a third recess 464 for each third terminal 374 connected to the first terminal 370). 1-5 ). The third recess 464 may extend substantially parallel to the XZ plane. The third recess 464 may intersect the corresponding first recess 460 (e.g., vertically) and / or may be aligned with the middle of the prong 394 of the first terminal 370 and / or around the middle of the first recess 460 (e.g., in the Y direction). The plurality of fourth recesses 466 may include a fourth recess 466 for each third terminal 374 connected to the second terminal 372 (e.g., for each third terminal 374 6-10 ). The fourth recess 466 can extend generally parallel to the circuit board 324 and / or the XZ plane. The fourth recess 476 can intersect the corresponding second recess 462 (e.g., vertically) and / or can be aligned with the middle of the prong 404 of the second terminal 372 (e.g., in the Y direction). The third recess 464 and / or the fourth recess 466 can be tapered or chamfered, such as to facilitate insertion of the third terminal 374 into the first terminal 370 and the second terminal 372, respectively, and / or into the first terminal housing 376. The recesses 460, 462 can be configured to facilitate proper positioning of the terminals 370, 372 for connection with the third terminal 374 (as well as proper positioning prior to connection).

[0136] According to an embodiment, the first terminal 370 and the second terminal 372 can be inserted into the holes 440, 442 of the circuit board 324 (e.g., in the Z direction) and can be fixed therein, such as by welding and / or press-fit connection. The first terminal housing 376 can be disposed above the first and second terminals 370, 372 (e.g., as viewed in the Z direction) until the housing tabs 470A, 470B are inserted into and / or snapped into the third hole 444 of the circuit board 324, which can connect the first terminal housing 376 to the circuit board 324. The third terminal 374 can be inserted into the corresponding third and fourth recesses 464, 466 of the first and second terminals 370, 372 and / or the first terminal housing 376.

[0137] In an embodiment, such as in Fig.23 and Fig. 27 As generally shown in FIG. 3 , the upper cover 334 can then be moved toward the circuit board 324 so that the third terminal 374 is inserted into the terminal hole 484 of the inner wall 486 of the first connector portion 456. The third terminal 374 can extend through the inner wall 486 for connection with the connector terminal 352A of the first connector 352. In some configurations, the third terminal 374 can be inserted into the terminal hole 484 of the inner wall 486 of the first connector portion 356 before being inserted into the corresponding third and fourth recesses 464, 466 of the first and second terminals 370, 372 and / or the first terminal housing 376. Then, moving the upper cover 334 toward the circuit board 324 may include inserting the third terminal 374 into the corresponding third and fourth recesses 464, 466 of the first and second terminals 370, 372 and / or the first terminal housing 376, which may be a process of at least partially blind connection (e.g., the upper cover 334 may block at least some view during connection).

[0138] In an embodiment, the first 3741 of the third terminals 374 can be inserted into the first 3701 of the first terminals 370, and the second 3742 of the third terminals 374 can be inserted into the first 3721 of the second terminals 372. The first portion 4501 of the third terminal 3741 can be inserted into the first terminal 3701 and can be offset from the first portion 4502 of the third terminal 3742 in two directions such as the X direction and the Y direction. The second portion 4521 of the third terminal 3741 and the second portion 4522 of the third terminal 3742 can be offset from each other in one direction (such as the X direction), and / or can be substantially aligned with each other in the Y direction and the Z direction (for example, the third terminals 3741, 3742 can be arranged in a stacked and mirrored configuration). The electrical unit 320 may include a plurality of mirrored and stacked third terminal pairs 374, each of which can be connected to a corresponding pair of the first terminal 370 and the second terminal 372.

[0139] In an embodiment, such as in Fig.19 As generally shown in FIG. 3 , the electrical unit 320 may include one or more fourth terminals 490 that may be connected to the circuit board 324, and / or a fifth terminal 492 that may be connected to the one or more fourth terminals 490. The fourth terminal 490 may, for example, include the same or similar configuration as the first terminal 370, and may include a tab 500 and / or a mating portion 502, the mating portion 502 may include a prong 404. The tab 500 may be inserted into and / or soldered to a fourth hole 510 of the circuit board 324. The prong 404 may, for example, extend substantially parallel to the XZ plane. The fourth terminal 490 may be substantially planar, and may, for example, be spaced apart from each other by about 4 mm to about 5 mm, such as about 4.5 mm. The fourth terminal 490 may be spaced further apart than the first terminal 370 and the second terminal 372, because a higher current may be provided to the fifth terminal 492 than to the third terminal 374. For example, the fifth terminal 492 can be configured as a power terminal (e.g., for supplying power to the electrical unit 320), and the third terminal 374 can be configured as a data terminal. The fourth terminals 490 can be aligned with each other in a row / column to at least partially receive the fifth terminal 492. A plurality of fourth terminals 490 can, for example, be connected to the same fifth terminal 492 to distribute a relatively high current from the fifth terminal 492.

[0140] According to an embodiment, the second terminal housing 378 may include one or more first recesses 512, such as for each fourth terminal 490. The first recess 512 may be, for example but not limited to, configured in the same or similar manner as the first recess 460 of the first terminal housing 376. The first recess 512 may extend upward from the bottom of the second terminal housing 378, such as extending generally parallel to the XZ plane. The second terminal housing 378 may include one or more second recesses 514. The second recesses 514 may, for example but not limited to, be connected together (e.g., end-to-end) to form an elongated recess that may be configured to receive the third portion 524 of the fifth terminal 492, such as if the third portion 524 is configured as a blade (e.g., instead of having a separate protrusion). The second recess 514 may be substantially parallel to the YZ plane and / or may be substantially aligned with the middle of the prong 394 (e.g., in the X direction). The second terminal housing 378 may be disposed over the fourth terminal 490 , such as until one or more of the housing tabs 472 snap into the circuit board 324 .

[0141] In an embodiment, such as in Fig.19, the fifth terminal 492 may include a first portion 520, a second portion 522, and / or a third portion 524. The first portion 520 may be substantially parallel to the third portion 524. The second portion 522 may be substantially perpendicular to the first portion 520 and / or the third portion 524. The second portion 522 may connect the first portion 520 with the third portion 524. The third portion 524 may include a blade configuration or may include a protrusion similar to the protrusion of the fifth terminal 192. The third portion 524 may be inserted into a corresponding prong 204, such as to electrically connect the fifth terminal 492 with the fourth terminal 490 and / or the circuit board 324. For example, the same fifth terminal 492 may be connected to multiple fourth terminals 490. The first portion 520 may be thicker than the second portion 522 and / or the third portion 524, such as to be compatible with one or more terminals 454A of the external connector 454. The third portion 524 may be thinner than the first portion 520, such as to be compatible with the fourth terminal 490.

[0142] In an embodiment, the fifth terminal 492 can be inserted into the fourth terminal 490 and / or the second terminal housing 378, and then the upper cover 334 can be moved toward the circuit board 324 so that the fifth terminal 492 is inserted into the terminal hole 494 of the inner wall 496 of the second connector portion 358. The fifth terminal 492 can extend through the inner wall 496 for connecting with the connector terminal 354A of the second connector 354. For example, but not limited to, moving the upper cover 334 toward the circuit board 324 can include inserting the third terminal 374 into the first connector portion 356, and can include inserting the fifth terminal 192 into the second connector portion 358 (e.g., substantially simultaneously).

[0143] In some configurations, the fifth terminal 492 may be inserted into the terminal aperture 494 of the inner wall 496 of the second connector portion 358 before being inserted into the corresponding recess 514 of the fourth terminal 490 and / or the second terminal housing 378. Then, moving the upper cover 334 toward the circuit board 324 may include inserting the fifth terminal 492 into the corresponding second recess 514 of the fourth terminal 490 and / or the second terminal housing 378, which may be a process of at least partially blind connection. For example, but not limited to, moving the upper cover 334 toward the circuit board 324 may include inserting the third terminal 374 into the first and second terminals 370, 372, and may include inserting the fifth terminal 492 into the fourth terminal 490 (e.g., substantially simultaneously), one or both of which may be processes of at least partially blind connection.

[0144] In an embodiment, the second recess 514 may be tapered or chamfered, such as to facilitate insertion of the fifth terminal 492 into the fourth terminal 490 and / or the second terminal housing 378 .

[0145] According to an embodiment, in the assembled configuration, one or more third terminals 374 can extend from the upper cover 334, such as at least partially in the first connector portion 356, and / or the fifth terminal 492 can extend from the upper cover 334, such as at least partially in the second connector portion 358.

[0146] In an embodiment, the electrical unit 20, 320 may include more than one first terminal housing 76, 376 and / or more than one second terminal housing 78, 378 (and the terminals 70, 72, 74, 190, 192, 370, 372, 375, 490, 492 associated therewith), such as if the connector wall 36 or the top cover 334 includes additional connector portions 56, 58, 356, 358.

[0147] Embodiments of the electrical unit 320 may, for example, be configured to compensate for wide tolerances (e.g., in a direction perpendicular to the circuit board 324), such as by compensating for elongated connections between the third terminal 374 and the first and second terminals 370, 372, and / or by compensating for elongated connections between the fifth terminal 492 and the fourth terminal 490. For example, but not limited to, the prongs 394, 404 may be configured to make electrical connections along some, most, or all of the first portion 450 of the third terminal 374, which may allow for various relative positions between the third terminal 374 and the first and second terminals 370, 372 to compensate for tolerances.

[0148] In an embodiment, the terminal housing (e.g., terminal housing 76, 78, 376, 378) can be configured to facilitate positioning of the terminals (e.g., terminals 70, 72, 190, 370, 372, 490) on the circuit board 24, 324, and / or can facilitate insertion of the terminals (e.g., terminals 74, 192, 374, 492), such as by centering the terminals during insertion and / or by providing support during insertion (e.g., to limit damage to the terminals or the circuit board).

[0149] According to embodiments, the terminals of the electrical unit 20, 320 may be configured for various ranges of current. For example, but not limited to, the terminals 70, 72, 74, 190, 370, 372, 374, 490 may be configured for currents of about 3 A to about 30 A, and / or the terminals 192, 492 may be configured for currents of about 20 A to about 100 A. In some cases, smaller currents may involve smaller terminals and / or minimum spacing distances.

[0150] Various examples / embodiments for various devices, systems, and / or methods are described herein. Many specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples / embodiments described in the specification and illustrated in the accompanying drawings. However, those skilled in the art will appreciate that the examples / embodiments can be practiced without such specific details. In other instances, well-known operations, parts, and elements are not described in detail so as not to obscure the examples / embodiments described in this specification. Those of ordinary skill in the art will appreciate that the examples / embodiments described and illustrated herein are non-limiting examples, and therefore it can be appreciated that the specific structural and functional details disclosed herein can be representative and do not necessarily limit the scope of the embodiments.

[0151] References to "example", "in an example", "according to an example", "various embodiments", "according to an embodiment", "in an embodiment", or "an embodiment", or the like throughout the specification mean that a particular feature, structure, or characteristic described with respect to the example / embodiment is included in at least one embodiment. Therefore, the appearance of the phrases "example", "in an example", "according to an example", "in various embodiments", "according to an embodiment", "in an embodiment", or "an embodiment", or the like in the correct places throughout the specification does not necessarily refer to the same embodiment. In addition, particular features, structures, or characteristics may be combined in any correct manner in one or more examples / embodiments. Therefore, the particular features, structures, or characteristics illustrated or described in conjunction with one embodiment / example may be combined in whole or in part with the features, structures, functions, and / or characteristics of one or more other embodiments / examples without restriction, as long as such combination is not illogical or inoperative. In addition, many modifications may be made to adapt particular situations or materials to the teachings of the present disclosure without departing from the scope of the present disclosure.

[0152] It should be understood that references to individual elements are not necessarily so limited, but may include one or more such elements. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to help the reader understand the present disclosure and do not create limitations, particularly with respect to the position, orientation, or use of the examples / embodiments.

[0153] Mentions of engagement (e.g., attachment, connection, connection, and similar terms) should be interpreted broadly, and may include intermediate members between the connection of elements and relative motion between elements. Therefore, mentioning engagement does not necessarily mean that two elements are directly connected / connected and are in a fixed relationship relative to each other. The use of "for example" in this specification should be interpreted broadly and used to provide non-limiting examples of embodiments of the present disclosure, and the present disclosure is not limited to such examples. The use of "and" and "or" should be interpreted broadly (e.g., regarded as "and / or"). For example, but not limited to, the use of "and" does not necessarily require all the elements or features listed, and the use of "or" is inclusive, unless such a structure is illogical.

[0154] Although processes, systems, and methods may be described herein in conjunction with one or more steps in a particular sequence, it should be understood that these methods may be practiced with steps in a different order, by performing certain steps simultaneously, with additional steps, and / or by omitting certain described steps.

[0155] It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes may be made in detail or structure without departing from the disclosure.

Claims

1. An electrical unit, comprising: Circuit boards; a plurality of first terminals having respective first tabs and respective first mating portions, the first tabs being generally perpendicular to the first mating portions and being fixed to the circuit board; a plurality of second terminals having respective second tabs and respective second mating portions, the second tabs being generally perpendicular to the second mating portions and being fixed to the circuit board; a plurality of third terminals including a first male terminal and a second male terminal; and a terminal housing disposed above the plurality of first terminals and the plurality of second terminals and connected to the circuit board; wherein the first male terminal is at least partially disposed in a first one of the plurality of first terminals and comprises a first male terminal first portion and a first male terminal second portion; The second male terminal is at least partially disposed in a first one of the plurality of second terminals and includes a second male terminal first portion and a second male terminal second portion; at least two of the second tabs are offset from at least two of the first tabs in a first offset direction and a second offset direction; The first portion of the first male terminal and the first portion of the second male terminal are offset in two offset directions; and The first male terminal second portion and the second male terminal second portion are substantially aligned in two alignment directions so that the first male terminal and the second male terminal convert the staggered configuration of the plurality of first terminals and the plurality of second terminals into a parallel configuration, The plurality of first terminals and the plurality of second terminals are planar terminals, each including a pair of prongs.

2. The electrical unit according to claim 1, wherein: The top edges of the plurality of first terminals are disposed at a first distance from the circuit board; The bottom edges of the plurality of second terminals are disposed at a second distance from the circuit board; The second distance is equal to or less than the first distance; The top edges of the plurality of second terminals are disposed at a third distance from the circuit board; The third distance is greater than the first distance and the second distance.

3. The electric unit of claim 2, comprising an electric unit housing disposed at least partially around the circuit board and having side walls and a connector wall.

4. The electrical unit according to claim 3, wherein: The first male terminal is at least partially disposed in the connector wall; and The second male terminal is at least partially disposed in the connector wall.

5. The electrical unit according to claim 4, wherein: The terminal housing includes a plurality of first recesses, a plurality of second recesses, a plurality of third recesses, and a plurality of fourth recesses; The plurality of first terminals are disposed in the plurality of first recesses; The plurality of second terminals are disposed in the plurality of second recesses; The first male terminal is partially disposed in one of the plurality of third recesses; The second male terminal is partially disposed in one fourth recess of the plurality of fourth recesses; and The plurality of third recesses and the plurality of fourth recesses are substantially perpendicular to the plurality of first recesses and the plurality of second recesses.

6. The electrical unit of claim 1, wherein: The plurality of third terminals include a plurality of first male terminals at least partially disposed in corresponding first terminals among the plurality of first terminals; and The plurality of third terminals include a stepped configuration and are parallel to the circuit board. 7 . The electric unit according to claim 6 , wherein the terminal housing includes a plurality of recesses that facilitate insertion of the plurality of first male terminals into the plurality of first terminals.

8. The electrical unit according to claim 1, wherein: The terminal housing includes a plurality of first recesses, a plurality of second recesses, a plurality of third recesses, and a plurality of fourth recesses; The plurality of third recesses and the plurality of fourth recesses are substantially perpendicular to the plurality of first recesses and the plurality of second recesses; At least one of the plurality of third recesses intersects with a corresponding first recess of the plurality of first recesses, such that the at least one third recess is aligned with a middle portion of a pair of prongs of one of the plurality of first terminals; and The plurality of fourth recesses intersect corresponding second recesses of the plurality of second recesses.

9. The electrical unit according to claim 8, wherein: The plurality of first recesses and the plurality of second recesses extend to the front wall of the terminal housing; The plurality of first recesses include a first height; The plurality of second recesses comprises a second height; and The second height is greater than the first height.

10. The electrical unit according to claim 9, wherein: The plurality of third recesses are disposed at a first distance from the circuit board; The plurality of fourth recesses are disposed at a second distance from the circuit board; The second distance is greater than the first distance; and The plurality of third recesses and the plurality of fourth recesses are chamfered to facilitate insertion of the plurality of third terminals.

11. The electrical unit according to claim 1, wherein: The first offset direction is an X direction, and the second offset direction is a Y direction; and The prongs of the plurality of first terminals and the prongs of the plurality of second terminals are offset in the Y direction and the Z direction.

12. A method of assembling an electrical unit according to claim 1, the method comprising: connecting the first tabs of the plurality of first terminals to the circuit board; connecting the second tabs of the plurality of second terminals to the circuit board such that each second tab is at least partially offset from each first tab of the plurality of first terminals in the first offset direction and the second offset direction; disposing the terminal housing above the plurality of first terminals and the plurality of second terminals; and The terminal housing is connected to the circuit board.

13. The method according to claim 12, wherein: The terminal housing is disposed over the plurality of first terminals after the first tab and the second tab are connected to the circuit board.

14. A method of assembling an electrical unit, the method comprising: connecting the first tabs of the plurality of first terminals to the circuit board; connecting second tabs of a plurality of second terminals to the circuit board such that each second tab is at least partially offset from each first tab of the plurality of first terminals in a first offset direction and a second offset direction; disposing a terminal housing over the plurality of first terminals and the plurality of second terminals; connecting the terminal housing to the circuit board; Inserting a plurality of third terminals into the connector portion of the connector wall, the plurality of third terminals comprising a first male terminal and a second male terminal, the first male terminal comprising a first male terminal first portion and a first male terminal second portion, the second male terminal comprising a second male terminal first portion and a second male terminal second portion; and moving the connector wall to insert the plurality of third terminals into the plurality of first terminals, the plurality of second terminals, and the terminal housing; wherein moving the connector wall to insert the plurality of third terminals into the plurality of first terminals comprises: disposing the first male terminal at least partially in a first one of the plurality of first terminals; wherein moving the connector wall to insert the plurality of third terminals into the plurality of second terminals comprises: disposing the second male terminal at least partially in a first one of the plurality of second terminals; wherein the first male terminal first portion and the second male terminal first portion are offset in two offset directions, and the first male terminal second portion and the second male terminal second portion are substantially aligned in two alignment directions, so that after moving the connector wall, the first male terminal and the second male terminal convert the staggered configuration of the plurality of first terminals and the plurality of second terminals into a parallel configuration, The plurality of first terminals and the plurality of second terminals are planar terminals, each including a pair of prongs.

15. The method according to claim 14, wherein: The plurality of third terminals are arranged in a plurality of mirrored and stacked pairs.

16. The method of claim 14, comprising providing an electrical unit housing at least partially around the circuit board, wherein: The front edges of the plurality of first terminals and the plurality of second terminals are substantially aligned with the edge of the circuit board; The front wall of the terminal housing is substantially aligned with the edge of the circuit board; The side wall of the electric unit housing is disposed adjacent to the front wall of the terminal housing and the edge of the circuit board; and The connector wall is disposed adjacent to the side wall.

17. A method of assembling an electrical unit, the method comprising: connecting the first tabs of the plurality of first terminals to the circuit board; connecting the second tabs of the plurality of second terminals to the circuit board such that each second tab is at least partially offset from each first tab of the plurality of first terminals in a first direction and a second direction; disposing a terminal housing over the plurality of first terminals and the plurality of second terminals; connecting the terminal housing to the circuit board; inserting a plurality of third terminals into the connector portion of the connector wall; as well as moving the connector wall to insert the plurality of third terminals into the plurality of first terminals, the plurality of second terminals, and the terminal housing; Wherein, the plurality of first terminals include a first female terminal; The plurality of second terminals include a second female terminal; The plurality of third terminals include a first male terminal and a second male terminal; The first male terminal comprises a first male terminal first portion and a first male terminal second portion offset from the first male terminal first portion; The second male terminal comprises a second male terminal first portion and a second male terminal second portion offset from the second male terminal first portion; After moving the connector wall, the first male terminal first portion is at least partially disposed in the first female terminal, and the second male terminal first portion is at least partially disposed in the second female terminal; and The first male terminal second portion and the second male terminal second portion are offset in an offset direction and are substantially aligned in two alignment directions, The plurality of first terminals and the plurality of second terminals are planar terminals, each including a pair of prongs.

18. The method according to claim 17, wherein: The circuit board is substantially parallel to the XY plane and substantially perpendicular to the Z direction; and The offset direction is the Z direction, and the two alignment directions are the X direction and the Y direction.

19. The method according to claim 17, comprising: providing a plurality of fourth terminals; fixing the tabs of the plurality of fourth terminals to the circuit board; disposing a second terminal housing above the plurality of fourth terminals; connecting the second terminal housing to the circuit board; and inserting a rear portion of the fifth terminal into the second connector portion of the connector wall; Wherein, moving the connector wall includes inserting a front portion of the fifth terminal into the plurality of fourth terminals and the second terminal housing.

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