Electronic control module with a cover for checking pressed-in pins at right angles

Abstract

Device comprising: an electronic control module (10) comprising: a housing (12); a cover (38) having a first portion (38a) and a second portion (38b) that is bendable relative to the first portion (38a); a plurality of pins (20); and a circuit board (40) connected to the first portion (38a) of the cover (38); wherein the plurality of pins (20) are press-fitted into the circuit board (40) upon connection of the cover (38) to the housing (12), wherein the plurality of pins (20) are verifiable for correct positioning relative to the circuit board (40), and wherein the second portion (38b) is then attached to the housing (12); wherein the second portion (38b) of the cover (38) is bendable relative to the first portion (38a) to enable verification of the plurality of pins (20) after the plurality of pins (20) have been press-fitted into the circuit board (40) upon connection of the first portion (38a) of the cover (38) to the housing (20).

Description

Field of the InventionThe invention relates generally to an electronic control module having press-fit pins at right angles, the module comprising a cover having a portion that is bendable to allow testing of the pins after the pins have been press-fit into a circuit board.BACKGROUND OF THE INVENTIONElectronic control modules are well known, wherein some types of electronic control modules include a set of pins shaped to a right angle (90°) to allow positioning of the pins such that one end of the pins extends outward and is part of a connector, and the other end of the pins extends into and contacts a circuit board. These modules typically comprise a housing, wherein the circuit board, together with further components, is arranged in the housing, and wherein the housing is encapsulated with the pins such that a portion of the pins extends into the housing, and wherein a portion of the pins extends out of the housing and is part of the connector.These modules also typically include a cover that is assembled to the housing during assembly. Some modules are designed such that the cover is assembled to the housing during assembly using fasteners such as screws. There is also a subunit comprising a circuit board laminated to a cover, which subunit is then pressed onto the pins so that the pins are pressed into the circuit board. The screws are then used for permanently securing the cover to the housing. However, during this process, it is difficult to visually check the resulting press-in interface between the circuit board and the pins. To solve this problem, some attempts have been made by inserting a separate opening into the cover to allow access to the pins after the cover has been connected to the housing, and then attaching one or two additional cover plates to the cover after the pins have been checked. However, this process is expensive and requires additional manufacturing steps. These types of covers are typically made from an injection molding material that is expensive and includes additional components and manufacturing steps due to the cover plates, seals, and screws used to seal the (so-called "window") openings in the injection mold. Window openings are needed for checking the press-in interface after the circuit board has been installed and the pins have been press-fitted into the board.Another process used in assembling these modules involves placing the circuit board into the housing such that the pins are press fit into the circuit board and then placing a gap fill material on the circuit board followed by a sealant and subsequent cover. This way of assembly requires the circuit board to have a larger surface area due to the use of the gap fill material, typically the board being mounted with screws extending through the housing, the circuit board, and into the cover.U.S. Pat. No. 5,978,226 A discloses a switching and control device for motor vehicles. When the cover of the switching and control device is removed, a printed circuit board can be pushed into the plug-in housing from the front and is pressed onto the thermally conductive contact surfaces by a wedge tapering conically in the insertion direction. This is because the wedge rests with the upper wedge side surface against an upper housing wall and presses the printed circuit board with the lower wedge side surface against the bearing surfaces with increasing force during insertion.DE 197 01 854 C1 discloses a housing for installation in motor vehicles for accommodating a flexible printed circuit board equipped with electronic components and formed from frame parts and a first and second carrier plate. The frame parts consist of profiled strips with a T-profile and of cutter strips. The first and second support plates each consist of a metallic plate.Accordingly, there is a need for an electronic control module that allows connection between the circuit board and the pins during assembly, allows visual inspection of the press-in interface after connection to the circuit board, and provides an appropriate connection between the cover and the housing while minimizing costs and manufacturing steps.SUMMARY OF THE INVENTIONThe present invention resides in an electronic control module comprising a cover having a circuit board, the cover permitting visual inspection of the press-in interface after the pins have been press-fitted into a circuit board after the cover and housing are assembled.In one embodiment, the present invention is an electronic control module that includes a housing, a cavity formed as part of the housing, and a connector, the connector being part of the housing. The control module also includes a plurality of pins, each pin having a first end and a second end. A portion of the housing is integrally formed around the plurality of pins such that the first end of each pin of the plurality of pins is a part of the connector, and wherein the second end of each pin of the plurality of pins is disposed in the cavity. The control module also includes a cover having a large portion and a small portion, the small portion being bendable relative to the large portion. An adhesive connects the circuit board to the large portion of the cover, the small portion of the cover being bendable relative to the large portion to enable inspection of the plurality of pins after the plurality of pins are press-fitted into the circuit board after connecting the cover to the housing. A sealant is disposed between a portion of the cover and the housing to provide a seal between the cover and the housing.The connector includes a shroud integrally formed with the housing, and the first end of each pin of the plurality of pins extends out of the housing such that the first end of each pin of the plurality of pins is substantially surrounded by the shroud.There is at least one fastening element formed integrally with the housing, wherein at least one passage is surrounded by the fastening element. A fastener is inserted through the feedthrough to mount the electronic control module in the engine compartment or other area of a vehicle.Each pin of the plurality of pins is configured such that the first end of the plurality of pins is disposed about 90° relative to the second end of each pin of the plurality of pins. This allows the pins to connect a portion of the connector and to the printed circuit board.According to one embodiment, the electronic control module is constructed by forming a subassembly that includes a populated circuit board, which in one embodiment may be a printed circuit board (PCB) laminated to a cover with a pressure sensitive adhesive or a thermally conductive adhesive. A sealant is then applied to a portion of a housing.The subunit is formed such that a pattern is embossed in the cover to provide the cover with the small portion that can be bent at least twice without breaking off. The pattern also prevents the still moist seal from leaking. Due to the pattern embossed in the cover, a portion of the cover is positioned such that the press-fit pins can be visually inspected for a correct press-fit interface. Once the pins have been checked, the cover is bent straight using screws to attach the cover to the housing.In one embodiment, the cover is made of metal and may be made of aluminum sheet, or the cover could be made of coated steel instead of the aluminum. In other embodiments, fasteners are integrated into the cover with protruding material serving as metal spacers.It is therefore an object of this invention to reduce the cost of an electronic control module by replacing an injection molded cover with a less expensive cover.It is a further object of this invention to reduce manufacturing costs by omitting the process steps associated with the additional components required to cover and seal the (window) openings.It is yet another object of this invention to reduce the size of the electronic control module by omitting a gap fill material and the necessary screws and spacers, and instead using a pressure sensitive adhesive or a thermally conductive adhesive to laminate the circuit board to the cover.It is yet another object of this invention to eliminate the need for an aperture for performing the pin check and the additional components used to seal the aperture.It is yet another object of this invention to eliminate placement of the circuit board on mounting posts that require specific socket locations and heights for pressing onto the PCB.Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It is understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.Brief Description of the DrawingsThe present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: FIG. 1 is a first perspective view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 2 is a second perspective view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 3 is a side view of a subassembly that is part of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 4 is a first section side view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 5 is a second section side view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 6 is a third section side view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 7 is an exploded view of an electronic control module assembly in accordance with embodiments of the present invention; FIG. 8 is a partial sectional view of an electronic control module assembly in accordance with embodiments of the present invention; and FIG. 9 is a sectional side view of an alternative embodiment of an electronic control module assembly in accordance with embodiments of the present invention.Detailed Description of the Preferred EmbodimentsThe following description of the preferred embodiment or embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.Referring now to the figures, an electronic control module constructed in accordance with the present invention is shown generally at 10. The module 10 includes a housing 12 that includes a cavity, generally indicated by reference numeral 14. Integrally formed with the housing 12 is a shroud 16 which is part of a connector generally shown at 18. The connector 18 also includes a plurality of pins 20 where the housing 12 is molded around the pins 20 such that a first end 20 aof the pins 20 extends out of the housing 12 and is surrounded by the casing 16, with a second end 20 bof each of the pins 20 being disposed in the housing 12. In this embodiment, the pins 20 are right angle pins 20, with the first end 20a of each pin 20 being disposed at a 90° angle relative to the second end 20b of each pin 20. The second end 20b is disposed in the cavity 14 and projects outwardly from the cavity 14 as shown in Figs. 4 to 8.Cavity 14 also includes a flat portion, generally shown at 14a, and a deep portion, generally shown at 14b, pins 20 being located primarily in deep portion 14b. The housing 12 also includes an outer rim 22 substantially surrounding the perimeter of the cavity 14. Adjacent the rim 22 is a stepped portion 24 having an inner step and an outer step, with a sealant 26 applied to the inner step of the stepped portion 24 during assembly. Although a sealant 26 is referred to, it is within the scope of the invention that a gasket or other components may be used.Also formed as part of the housing 12 along the outer rim 22 is a series of threaded apertures 28 which receive fasteners such as screws 30. In addition, fasteners 32 are integrally formed with the housing 12 that are used to secure the module 10 within a vehicle, such as an engine compartment or the like. The fasteners 32 may optionally include fixed grommets 34 where fasteners such as bolts may be inserted through the grommets 34 to form a more stable connection with the vehicle.The module 10 also includes a subassembly, generally indicated at reference numeral 36 in Figures 3 and 7, which includes a cover 38 and a circuit board, which in this embodiment is a printed circuit board (PCB) 40. The cover 38 includes two portions, a large portion 38a and a small portion 38b. Both portions 38a,b include apertures 44 where during assembly the screws 30 are inserted through the apertures 44 of the cover 38 and into the threaded apertures 28 of the housing 12. The PCB 40 is attached to the large portion 38 aof the cover 38 by means of an adhesive 42, which in this embodiment may be a pressure sensitive adhesive (PSA=Pressure Sensitive Adhesive) or a thermally conductive adhesive (TCA= Thermal Conductive Adhesive).The small portion 38b of the cover 38 is movable relative to the large portion 38a due to a joint 46. The small portion 38b also includes a recessed portion 48 into which the second end 20b of the pins 20 extends after the small portion 38b is connected to the housing 12, providing a clearance between the second end 20b of the pins 20 and the cover 38.During assembly, the housing 12 is cast around the pins 20 such that the pins 20 are formed as shown in the figures. The sealant 26 is then applied to the inner step of the stepped portion 24. The PCB 40 is then attached to the cover 38 by means of the adhesive 42 to form the subunit 36. Once the subassembly 36 has been formed, the cover 38 is positioned relative to the housing 12 such that the outer edge of the cover 38 contacts the outer step of the stepped portion 24, with a portion of the sealant 26 in contact with the large portion 38a, with the openings 44 of the large portion 38a of the cover 38 aligned with corresponding threaded openings 28, and with screws 30 inserted through the openings 44 of the large portion 38a and into the corresponding threaded openings 28 of the housing 12 for connecting the cover 38 to the housing 12.When the large portion 38a of the cover 38 is connected to the housing 12, the second ends 20b of the pins 20 are press-fitted into the PCB 40 to the position shown in Figs. 5 to 6 and 8. During this part of the assembly process, the small portion 38b remains at an angle 50 relative to the large portion 38a as shown in Figs. 3, 5 and 7-8. In this embodiment, the angle 50 is about 90°, but it is within the scope of the invention that other angles may be used.After the large portion 38 aof the cover 38 has been connected to the housing 12, the second ends 20 bof the pins 20 are pressed into the PCB 40, checking the pins 20 to ensure that they are correctly positioned relative to the PCB 40. Typically, the height of the pins 20 is checked to determine whether the pins 20 are correctly positioned. This allows visual inspection of the pins 20 when the PCB 40 is connected to the cover 38, and eliminates the need for a window to be formed as part of the cover 38 to allow visual inspection of the pins 20, and eliminates additional components used to seal the window. Once the pins 20 are checked and it is verified that the pins 20 are in the correct position, the small portion 38b of the cover 38 is pivoted to place the outer edge of the small portion 38b in contact with the outer step of the stepped portion 24, with a part of the sealant 26 in contact with the small portion 38b, and with the openings 44 of the small portion 38b aligned with the threaded openings 28 of the housing 12. Screws 30 are then inserted through the openings 44 of the small portion 38b and into the threaded openings 28 of the housing 12 to secure the small portion 38b to the housing 12, as shown in Figures 2 and 6. As the small portion 38 bis connected to the housing 12, the second end 20 bof the pins 20 extends at least partially into the recessed portion 48, as shown in FIG. 6.The cover 38 is made of a sheet metal material, such as aluminum, as opposed to an injection molding material that is more expensive. The joint 46 typically has a geometry or pattern that is embossed to allow the small portion 38b of the cover 38 to be bent at least twice during assembly relative to the large distance 38a so that the small portion 38b can be bent between the position shown in Figures 3, 5 and 7 to 8 and the position shown in Figures 2 and 6.An alternative embodiment of the invention is shown in Figure 9, wherein like reference numerals designate like elements. In this embodiment, a gap fill material 56 is disposed that is deposited on the circuit board 40 around the second end 20 bof each of the pins 20, providing additional heat dissipation.

Claims

An apparatus comprising: an electronic control module (10) comprising: a housing (12); a cover (38) having a first portion (38a) and a second portion (38b) bendable relative to the first portion (38a); a plurality of pins (20); and a board (40) connected to the first portion (38a) of the cover (38); wherein the plurality of pins (20) are press fit into the circuit board (40) upon connecting the cover (38) to the housing (12), wherein the plurality of pins (20) are checkable for proper positioning relative to the circuit board (40), and wherein the second portion (38b) is then attached to the housing (12); wherein the second portion (38b) of the cover (38) is bendable relative to the first portion (38a) to enable checking of the plurality of pins (20) after the plurality of pins (20) have been pressed into the circuit board (40) upon connecting the first portion (38a) of the cover (38) to the housing (20).The device of claim 1, further comprising a connector (18), wherein a first end (20a) of each pin (20) of the plurality of pins (20) is part of the connector (18).The device of claim 2, wherein the connector (18) further comprises a shroud (16) integrally formed as part of the housing (12), wherein the first end (20a) of each pin (20) of the plurality of pins (20) is disposed in the shroud (16).The device of claim 1, wherein a portion of the housing (12) is molded around a portion of each pin (20) of the plurality of pins (20).The device of claim 1, further comprising a cavity (14) formed as part of the housing (12), wherein a portion of the pins (20) are disposed in the cavity (14).The apparatus of claim 1, further comprising a sealing means (26) disposed between the cover (38) and the housing (12) such that the sealing means (26) provides a sealing function when the cover (38) is attached to the housing (12).The apparatus of claim 1, further comprising an adhesive (42), wherein the adhesive (42) connects the cover (38) to the circuit board (40).The apparatus of claim 7, wherein the cover (38) further comprises: a large portion (38a) connected to the circuit board (40) by the adhesive (42); and a small portion (38b) connected to and bendable relative to the large portion (38a); wherein the small portion (38b) is positioned at an angle relative to the large portion (38a) when the cover (38) is assembled to the housing (12), and wherein after assembling the cover (38) to the housing (12), the small portion (38b) is displaced relative to the large portion (38a) and is connected to the housing (12).The device of claim 1, wherein the plurality of pins (20) further comprises a second end (20b), the second end (20b) of each pin (20) of the plurality of pins (20) being press fittable into the circuit board (40) upon connecting the cover (38) to the housing (12).The apparatus of claim 1, further comprising: at least one fastener (32) integrally formed with the housing (12); and at least one feedthrough (34) surrounded by the at least one fastener (32); wherein a fastener is insertable through the at least one feedthrough (34) to connect the electronic control module (10) to a vehicle.An electronics module (10) comprising: a housing (12); a plurality of pins (20), each pin (20) of the plurality of pins (20) having a first end (20a) and a second end (20b), a portion of the housing (12) being integrally formed around the plurality of pins (20); a circuit board (40); a cover (38) having a first portion (38a) to which the circuit board (40) is connected and a second portion (38b) bendable relative to the first portion (38a); and a sealing means (26) disposed on a portion of the cover (39); wherein the second portion (38b) is in a first position when connecting the cover (38) to the housing (12), thereby enabling checking of the plurality of pins (20), and wherein after checking of the plurality of pins (20) the second portion (38b) is displaced to a second position and connected to the housing (12), wherein the second portion (38b) of the cover (38) is bendable relative to the first portion (38a) in order to enable checking of the plurality of pins (20) after the plurality of pins (20) has been pressed into the circuit board (40) when connecting the first portion (38a) to the housing (12).The electronics module (10) of claim 11, further comprising an adhesive (42) that bonds the circuit board (40) to the first portion (38a).The electronics module (10) of claim 11, wherein the connector (18) further comprises: a shroud (16) integrally formed with the housing (12); wherein the first end (20a) of each pin (20) of the plurality of pins (20) extends out of the housing (12) and is surrounded by the shroud (16).The electronics module (10) of claim 13, further comprising: at least one fastener (32) integrally formed with the housing (12); and at least one feedthrough (34) surrounded by the at least one fastener (32); wherein a fastener for connecting the electronics module (10) to a vehicle is insertable through the at least one feedthrough (34).The electronics module (10) of claim 11, wherein the first portion (38a) of the cover (38) further comprises a large portion (38a), the circuit board (40) being attachable to the large portion (38a).The electronics module (10) of claim 15, wherein the second portion (38b) further comprises a small portion (38b) that is bendable and connected to the housing (12) after the position of each pin (20) of the plurality of pins (20) has been checked.The electronics module (10) of claim 11, further comprising a cavity (14) formed as part of the housing (12), wherein a portion of the pins (20) are disposed in the cavity (14).An electronic control module (10) comprising: a housing (12); a cavity (14) formed as part of the housing (12); a connector (18), wherein the connector (18) is part of the housing (12); a plurality of pins (20), each pin (20) of the plurality of pins (20) having a first end (20a) and a second end (20b), wherein a portion of the housing (12) is integrally formed around the plurality of pins (20) such that the first end (20a) of each pin (20) of the plurality of pins (20) is part of the connector (18), and wherein the second end (20b) of each pin (20) of the plurality of pins (20) is disposed in the cavity (14); a sealant (26); a cover (38) having a large portion (38a) and a small portion (38b), the small portion (38b) being bendable relative to the large portion (38a), and the sealing means (26) being disposed between a part of the cover (38) and the housing (12) to provide a seal between the cover (38) and the housing (12); a circuit board (40); and an adhesive (42) connecting the circuit board (40) to the large portion (38a) of the cover (38); wherein the small portion (38b) of the cover (38) is bendable relative to the large portion (38a) to enable checking of the plurality of pins (20) after the plurality of pins (20) are press-fitted into the circuit board (40) upon connecting the large portion (38a) to the housing (12).The electronic control module (10) of claim 18, wherein the connector (18) further comprises: a shroud (16) integrally formed with the housing (12); wherein the first end (20a) of each pin (20) of the plurality of pins (20) extends out of the housing (12) such that the first end (20a) of each pin (20) of the plurality of pins (20) is substantially surrounded by the shroud (16).The electronic control module (10) of claim 18, further comprising: at least one fastener (32) integrally formed with the housing (12); and at least one feedthrough (34) surrounded by the at least one fastener (32); wherein a fastener is insertable through the at least one feedthrough (34) for connecting the electronic control module (10) to a vehicle.The electronic control module (10) of claim 18, wherein each pin (20) of the plurality of pins (20) is configured such that the first end (20a) of each pin (20) of the plurality of pins (20) is disposed about 90° relative to the second end (20b) of each pin (20) of the plurality of pins (20).

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