HIGH-PERFORMANCE WIRE CONNECTION WITH CONDUCTOR PLATE
The printed circuit board assembly with elastically deformable spring segments and a casing ensures robust high-current connections by maintaining contact pressure, addressing the inefficiencies of conventional spring contacts in automotive applications.
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-09-16
- Publication Date
- 2026-03-26
AI Technical Summary
Existing electrical connections in vehicles, particularly in high-current automotive applications, face challenges in providing robust and efficient connections capable of handling high currents without overheating, as conventional spring contacts are primarily designed for terminal-to-terminal applications and not optimized for wire-to-terminal connections.
A printed circuit board assembly featuring a terminal block with elastically deformable spring segments and a casing with legs that ensure a strong, high-current connection by maintaining contact pressure and preventing outward displacement of the spring segments during assembly.
The solution enables high-performance electrical connections capable of continuously transmitting 30 amperes and intermittently 140 amperes without overheating, providing a robust and reliable interface for high-current automotive applications.
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Abstract
Description
AREA OF INVENTION
[0001] The embodiments described herein relate to electrical connections and in particular to a high-performance wire connection with a printed circuit board. BACKGROUND
[0002] A vehicle such as a car, truck, sport utility vehicle (SUV), crossover, minivan, marine craft, aircraft, off-road vehicle, motorhome, or other suitable vehicle typically incorporates various electric motor-vehicle interface locations. Electric motors can be used throughout the vehicle for a variety of functions, such as power steering, steering column adjustment, and other functionalities. These motors usually receive instructions from a circuit board assembly that provides the motor-vehicle interface. Various electronic components are arranged and interconnected on circuit boards (e.g., a printed circuit board), and therefore, design and packaging considerations are important for the end-use application.
[0003] Electrical interfaces for connecting a terminal to a wire typically require welding in high-current automotive applications. For example, 30 A continuous current with 140 A short-term current may be required. The requirements and design considerations for such high-power applications differ from those of home electronics with 15 A currents. The automotive industry uses spring contacts for terminal-to-terminal applications, but not for wire-to-terminal applications. SUMMARY
[0004] According to one aspect of the disclosure, a printed circuit board assembly for a vehicle steering system includes a printed circuit board. The printed circuit board assembly also includes a terminal block that is functionally attached to a surface of the printed circuit board, the terminal block being made of an elastically deformable material and comprising a first spring segment and a second spring segment. The printed circuit board assembly further includes a wire that is arranged between and in contact with the first and second spring segments.
[0005] According to another aspect of the disclosure, a printed circuit board assembly for a vehicle steering system includes a printed circuit board. The printed circuit board assembly also includes a casing that defines a recess with a terminal block attached in the recess, the terminal block enclosing a first spring segment and a second spring segment. The printed circuit board assembly further includes a wire extending from the printed circuit board and positioned between and in contact with the first and second spring segments.
[0006] According to yet another aspect of the disclosure, a printed circuit board assembly for a vehicle steering system includes a printed circuit board. The printed circuit board assembly also includes a terminal block that is functionally attached to a surface of the printed circuit board, the terminal block being made of an elastically deformable material. The printed circuit board assembly includes a plastic shell, the shell comprising a base, a first leg, and a second leg, the first leg and the second leg extending from the base of the shell toward the printed circuit board. The printed circuit board assembly further includes a wire that is functionally connected to the shell and arranged between and in contact with the terminal block.
[0007] These and other advantages and features will become clearer from the following description in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The subject matter considered to be the invention is specifically highlighted and clearly claimed in the claims at the end of the patent specification. The foregoing and further features and advantages of the invention will become clear from the following detailed description in conjunction with the accompanying drawings, which: Fig. 1 is a perspective view of a printed circuit board with various wire-with terminal connections; Fig. 2 a perspective view of a wire which is connected to a terminal block of the printed circuit board in a first mounting position of the wire; Fig. 3 is a perspective view of the wire, which is connected to the terminal block of the circuit board in a second mounting position of the wire; Fig. 4 illustrates a wire which, according to another aspect of the disclosure, is connected to a terminal block in a first assembly position; and Fig. Figure 5 illustrates the wire which, in a second mounting position, connects to the terminal block of the Fig. 4 is connected. DETAILED DESCRIPTION
[0009] The following explanation is directed at various embodiments of the disclosure. Although one or more of these embodiments may be explained and / or illustrated in more detail than others, the disclosed embodiments should not be interpreted or otherwise used as limiting the scope of the disclosure, including the claims. Furthermore, a person skilled in the art will understand that the following description is broad and that the explanation of each embodiment is intended only as an example of that embodiment and is not meant to imply that the scope of the disclosure, including the claims, is limited to that embodiment.
[0010] As described, a vehicle such as a passenger car, truck, sport utility vehicle (SUV), crossover, minivan, marine craft, aircraft, off-road vehicle, motorhome, or other suitable vehicle typically incorporates various motor-vehicle interface positions. The motors described herein can be used throughout the vehicle for a variety of functions, such as power steering, steering column adjustment, and other functionalities. The electrically driven applications require circuit boards with a variety of electrical connections. The embodiments disclosed herein provide a more robust electrical terminal block for such connections.
[0011] Now, referring to Fig. Figure 1 shows a section of a printed circuit board assembly, generally designated by reference numeral 10. The printed circuit board assembly 10 includes a printed circuit board 11 having a plate area 12. Various electronic components are electrically connected to the plate area. As shown, one or more terminals 14 are attached to the plate area 12 of the printed circuit board 11 and extend away from the plate area 12. An electrical wire 16 can be connected to each terminal 14 to establish an electrical connection between an electronic component 18 and the printed circuit board 11. It is understood that the electronic component 18 connected to the printed circuit board 11 via the wire 16 can be various electronic components commonly used in automotive steering applications.
[0012] The embodiments disclosed herein enable an electrical connection interface with a large contact area and high contact force, capable of conducting high currents without overheating the contact. For example, the term "high-performance connection," as used herein, refers to a connection capable of continuously transmitting a current of 30 amperes—or more—and, for short periods, 140 amperes—or more. This is greater than that found in consumer electronics and allows for a higher direct current and a direct connection between the wire 16 and the printed circuit board 11.
[0013] Now, referring to Fig. 2 and Fig. Figure 3 shows in more detail the electrical connection between the wire 16 and the circuit board 11 via the terminal block 14.
[0014] Terminal 14 closes according to the diagram in Fig. 2 and Fig. In the embodiment shown in Figure 3, a first spring segment 22 and a second spring segment 24 are included. In some embodiments, the first spring segment 22 and the second spring segment 24 are completely separate components, while other embodiments may include a one-piece element with a base that connects the two spring segments 22 and 24. The terminal block 14 is soldered to the surface 12 of the printed circuit board 11 and, in an assembled state of the printed circuit board assembly 10, serves as an interface between the wire 16 and the printed circuit board 11. The terminal block 14 is made of any suitable material exhibiting elastic deformation properties.For example, the first spring segment 22 and the second spring segment 24 can be made of spring steel or any other suitable material that ensures that the spring segments 22, 24 return to their initial state when not pre-tensioned from the initial position.
[0015] A casing 20 is functionally connected to the wire 16 and the electronic component 18, which are to be connected to the terminal block 14. In some embodiments, the casing is made of plastic. The casing 20 comprises a base 30, a first leg 32, and a second leg 34. The first leg 32 and the second leg 34 extend from the base 30 of the casing 20 toward the surface 12 of the printed circuit board 11. In the illustrated orientation of the Fig. 2 and Fig. 3. The first leg 32 and the second leg 34 extend downwards from the base 30 towards the plate surface 12. The first leg 32 and the second leg 34 define a gap 36 between them. When the printed circuit board assembly 10 is mounted, the first spring segment 22 and the second spring segment 24 are located within the gap 36 between the first leg 32 and the second leg 34, as shown in Fig. Figure 3 shows the wire 16 being arranged between the first leg 32 and the second leg 34.
[0016] The first leg 32 extends from the base 30 to a distal tip 38 of the first leg, defining a length of the first leg between the base 30 and the distal tip 38 of the first leg. Similarly, the second leg 34 extends from the base 30 to a distal tip 40 of the second leg, defining a length of the second leg between the base 30 and the distal tip 40 of the second leg. As shown, the length of the first leg is greater than the length of the second leg. The relative leg length (i.e., the longer length of the first leg) ensures that the distal tip 38 of the first leg reaches the terminal 14 before the distal tip 40 of the second leg reaches the terminal 14, since the terminal 14 extends at a substantially uniform distance from the plate surface 12 of the printed circuit board 11.The first leg 32 and the second leg 34 are spaced apart to position the legs 32, 34 at the outer edges 42 and 44 respectively of the first spring segment 22 and the second spring segment 24 when the sheath 20 and consequently the wire 16 are moved closer to the plate surface 12.
[0017] During assembly, the sleeve 20 is moved closer to the plate surface 12, and the first leg 32 slides along the outer edge 42 of the first spring segment 22. The first leg 32 is essentially rigid and does not allow the first spring segment 22 to be biased outwards when the wire 16 is inserted so that it comes into contact with the terminal 14. Meanwhile, as the sleeve 20 is moved closer to the plate surface 12, the second leg 34 subsequently contacts the second spring segment 24 (relative to the contact of the first leg 32 with the first spring segment 22). The contact between the second leg 34 and the second spring segment 24 biases the elastically deformable second spring segment 24 towards the wire 16, promoting stronger contact between the terminal 14 and the wire 16.In some embodiments, the distal tip 40 of the second leg includes an angled end 46 to assist the initial contact between the second leg 34 and the second spring segment 24, thus enabling trouble-free insertion.
[0018] Now, referring to Fig. 4 and Fig. Figure 5 illustrates another embodiment of the printed circuit board assembly 10. In particular, a section of the interface between the wire 16 and a terminal block 114 is shown. In the illustrated embodiment, the terminal block 114 is fixed in a recess 116 defined by the shell 20, with the wire 16 functionally connected to the plate surface 12 of the printed circuit board 11. In the illustrated embodiment, the wire 16 extends away from the plate surface 12 and is pushed into the terminal block 114 of the shell 20. The terminal block 114 is a clamp or other spring-like device that is prevented from moving outwards by walls defining the recess 116. In some embodiments, the terminal block 114 has the features described above in conjunction with the embodiments of the Fig. 2 and Fig.The structure described in section 3 is shown. However, any suitable structure with elastically deformable segments for contacting the wire 16 is conceivable.
[0019] Although the invention has been described in detail in connection with only a limited number of embodiments, it is understood that the invention is not limited to the disclosed embodiments. Rather, the invention can be modified to include any number of variations, changes, substitutions, or equivalent arrangements not described herein, but which correspond to the basic concept and scope of protection of the invention. Even though various embodiments of the invention have been described, it is understood that aspects of the invention may only include some of the described embodiments. Furthermore, any feature, element, component, or advantage of any embodiment can also be used for any of the other embodiments. Accordingly, the invention is not to be considered as limited by the foregoing description.
Claims
[1] Printed circuit board assembly for a vehicle steering system, comprising: a circuit board; a terminal block that is functionally attached to a surface of the printed circuit board, wherein the terminal block is made of an elastically deformable material, and wherein the terminal block includes a first spring segment and a second spring segment; and a wire that is positioned between the first spring segment and the second spring segment and is in contact with them. [2] Printed circuit board assembly according to claim 1, wherein the wire is functionally connected to a sheath. [3] Printed circuit board assembly according to claim 2, wherein the casing is made of plastic. [4] Printed circuit board assembly according to claim 2, wherein the shell includes a base, a first leg and a second leg, the first leg and the second leg extending from the base of the shell towards the printed circuit board. [5] Printed circuit board assembly according to claim 4, wherein the first leg extends from the base to a distal tip of the first leg to define a length of the first leg, wherein the second leg extends from the base to a distal tip of the second leg to define a length of the second leg, wherein the length of the first leg is greater than the length of the second leg. [6] Printed circuit board assembly according to claim 5, wherein the first leg and the second leg define a gap between them, wherein the first spring segment and the second spring segment are located between the first leg and the second leg. [7] Printed circuit board assembly according to claim 6, wherein the second leg biases the second spring segment in the direction of the wire and the first spring segment. [8] Printed circuit board assembly according to claim 5, wherein the distal tip of the second leg includes an angled end. [9] Printed circuit board assembly according to claim 1, wherein the terminal block electrically connects the wire and the printed circuit board with a current of at least 30 amperes. [10] Printed circuit board assembly for a vehicle steering system, comprising: a circuit board; a casing defining a recess with a terminal block attached in the recess, the terminal block enclosing a first spring segment and a second spring segment; and a wire extending from the circuit board and positioned between the first spring segment and the second spring segment, and in contact with them. [11] Printed circuit board assembly according to claim 10, wherein the casing is made of plastic. [12] Printed circuit board assembly according to claim 10, wherein the terminal block electrically connects the wire and the printed circuit board with a current of at least 30 amperes. [13] Printed circuit board assembly for a vehicle steering system, comprising: a circuit board; a terminal block that is functionally attached to a surface of the printed circuit board, wherein the terminal block is made of an elastically deformable material; a plastic casing, the casing comprising a base, a first leg and a second leg, the first leg and the second leg extending from the base of the casing towards the circuit board; and a wire that is functionally connected to the casing and is positioned between and in contact with the terminal block. [14] Printed circuit board assembly according to claim 13, wherein the terminal block includes a first spring segment and a second spring segment. [15] Printed circuit board assembly according to claim 14, wherein the first leg extends away from the base section to a distal tip of the first leg to define a length of the first leg, wherein the second leg extends away from the base section to a distal tip of the second leg to define a length of the second leg, wherein the first length is greater than the second length. [16] Printed circuit board assembly according to claim 15, wherein the first leg and the second leg define a gap between them, wherein the first spring segment and the second spring segment are located between the first leg and the second leg. [17] Printed circuit board assembly according to claim 16, wherein the second leg biases the second spring segment in the direction of the wire and the first spring segment. [18] Printed circuit board assembly according to claim 15, wherein the distal tip of the second leg includes an angled end. [19] Printed circuit board assembly according to claim 13, wherein the terminal block electrically connects the wire and the printed circuit board with a current of at least 30 amperes.