Spliced ​​pin block for modular connectors

Abstract

Pin block module (1, 11, 12, 13) for insertion into a housing of a modular connector, wherein the pin block module (1, 11, 12, 13) comprises • a pin block carrier (2, 21, 22, 23) with a first connecting surface (24) and an opposite second connecting surface (25), • at least two pins (3, 31, 32, 33) extending through the pin block carrier (2, 21, 22, 23) such that each pin (3, 31, 32, 33) protrudes from the first connecting surface (24) and from the second connecting surface (25), characterized in that the pin block module (1, 11, 12, 13) further comprises • at least one splice element (4) that connects the at least two pins (3, 31, 32, 33) to each other in order to splice them.

Description

1. Field of the invention

[0001] The present disclosure relates to a pin block module for use in modular connectors. In particular, the present disclosure relates to a pin block module intended for insertion into a connector housing and comprising a pin block carrier with pins. 2. State of the art

[0002] In the field of modular connectors, it is common to use pin header modules for creating electrical connections within a housing. These pin header modules typically comprise multiple pins that extend through a carrier structure, enabling connections on both sides of the module. Known systems often require the use of separate plugs and terminals to connect multiple pins. This approach can be cumbersome and inefficient, as it requires additional components and assembly steps.

[0003] Previously, connecting pins to a pin block module required external devices such as external splicers or connectors, soldering, or crimp connections. While these external devices are designed to connect multiple pins, they require separate terminals and additional wire lengths to create the desired connections. This not only increases the complexity of the assembly process but also the overall size and weight of the connection. Furthermore, the additional cable lengths can introduce potential points of failure and reduce the reliability of the electrical connections.

[0004] Despite significant advances in modular connector technology, there remains a need for improved pin block modules that enable reliable connection of multiple pins without the drawbacks associated with separate connectors and additional cable lengths. Current methods using external splicers and clamps are not only inefficient but also prone to problems such as longer assembly times, higher manufacturing costs, and potential reliability issues.

[0005] The technical problem underlying the present invention is therefore to provide a pin block module that at least partially overcomes the disadvantages of known systems. 3. Summary of the invention

[0006] An objective of the present invention is to provide a pin block module that overcomes one or more of the disadvantages of known systems.

[0007] The aforementioned purpose is at least partially achieved by a pencil block according to claim 1.

[0008] A first aspect of the invention provides a pin block module for insertion into a housing of a modular connector, wherein the pin block module comprises a pin block carrier with a first connecting surface and an opposing second connecting surface, wherein at least two pins extend through the pin block carrier such that each pin projects from the first connecting surface and from the second connecting surface. This configuration enables an electrical connection through the pin block carrier.

[0009] The pin block module further comprises at least one splice element that connects the at least two pins together to splice them. In other words, the splice element serves to connect the at least two pins by creating a bridge or wire connection, thus effectively splicing them. In this way, the pins are electrically connected so that, for example, a signal input to one pin (signal input) can be effectively transmitted to two pins (signal output). The splice element provides an integrated solution for connecting the pins, which can improve the reliability and efficiency of the connection by reducing the need for separate plugs, terminals, and additional wire lengths. This integration can lead to a more compact and streamlined design, which simplifies assembly and reduces the overall complexity of the modular connector system. The use of a splice element, for example,within the pin block module, it can also lead to better electrical performance and durability by minimizing potential points of failure associated with conventional splicing methods.

[0010] The term "pin header module" refers to a component used in modular connectors, i.e., devices that allow electrical circuits to be connected and disconnected. The pin header module is part of the connector system that houses pins or terminals used to make electrical connections. The "splice element" is a component that joins or connects the pins within the module, thus enabling, for example, the integration of multiple wires into a single connection point, or vice versa. The "pin header carrier" is the structural part of the module that holds and supports the pins and splice elements.

[0011] Advantageously, at least one splice element is located within the pin block carrier. This placement of the splice element within the pin block carrier allows for a more compact and integrated configuration. Furthermore, this configuration can contribute to a cleaner and more efficient layout.

[0012] One embodiment involves forming the at least two pins and the splice element as a single piece. This means that the pins and the connector are manufactured as one unit rather than as separate components that are later assembled. This integration can improve the structural integrity and reliability of the pin block module by reducing the number of parts and potential points of failure. It also simplifies the manufacturing process, which can lower production costs and improve the uniformity of the final product. The integral design ensures a seamless connection between the pins and the splice element, which is inherently more robust than a connection between separate components. This can lead to improved electrical performance and durability, as there are no joints or interfaces that could wear out over time.This also brings significant advantages in terms of manufacturing efficiency, structural integrity and overall reliability of the pin block module.

[0013] In some embodiments, where the pins are to be inserted through the pin block carrier and where the pins and the splice element are formed in one piece, the splice element is advantageously shaped such that the at least two pins can be inserted through the pin block carrier and the splice element is received in the pin block carrier, i.e. without the splice element protruding from the pin block carrier.

[0014] The term "through-hole" refers to the way the pins are secured in the holder, requiring a precise insertion technique to ensure stability and alignment. The advantage of this design is that it maintains a streamlined profile and prevents any part of the connector from protruding beyond the pin block carrier. This results in a more compact and efficient assembly, reducing the risk of interference with other components and increasing the overall reliability and performance of the modular connector system.

[0015] When the pins are inserted through the pin block module using the splice element, the pins may have retaining barbs in their center to anchor them within the pin block carrier. These barbs have an insertion direction and are attached to the pin block carrier in the opposite direction to the insertion direction. The splice element includes a splice section located at the end of the barbs in the insertion direction, thus allowing for maximum barb length for anchoring within the pin block carrier during stapling. This design ensures secure pin retention and increases the stability and reliability of the modular connector assembly.

[0016] In some embodiments, the pins can be secured in the pin block holder by overmolding. Advantageously, the pins have a retention contour in the center of the pins, the splice element comprising at least two splice sections that form the retention contour. This retention contour is a specific shape or feature on the pin that helps to secure the pin within the pin block holder. Unlike barbs, the retention contour does not necessarily have an insertion direction. Instead, in this embodiment, the splice element is a component consisting of at least two splice sections, which are individual segments of the splice element that form the retention contour. They may have an irregular, rough, uneven, non-planar, or embossed surface to enhance the mechanical retention or bond between the overmolded pin block carrier material and the pins.The splice sections can define a through-hole through which molten material for the pin block carrier can pass during forming, thus holding the pins in the pin block carrier during forming.

[0017] Another way to integrate a splice element into a pin block module is to position the splice within the pin block carrier. This means the splice element is present within the pin block carrier before the two or more pins are mounted on it. In this configuration, the splice element is separate from the pins and positioned within the pin block carrier before the pins are mounted. This allows for a more efficient assembly process and offers greater connection flexibility because the splice element is pre-positioned within the pin block carrier, ensuring trouble-free pin mounting, and because the splice element can have a relatively complex shape.

[0018] The separate splice element can advantageously be a conductor track on a printed circuit board (PCB). This PCB trace increases versatility by enabling more complex and reliable electrical connections within the pin header module. Integrating the PCB into the pin header carrier enhances the module's functionality by providing a stable and organized platform for the conductor track and ensuring precise and efficient signal transmission between components. This arrangement simplifies the assembly and maintenance of the pin header module, as the PCB trace can be designed to meet specific electrical requirements and configurations.

[0019] The conductor track(s) of the separate splice element can, for example, directly connect at least two non-adjacent pins without connecting the intermediate pin between them. This is a feature that cannot be achieved if the splice element is integral with the pins to be spliced. This feature therefore enables a more efficient and targeted electrical connection within the pin block module by eliminating unnecessary intermediate connections.

[0020] In another embodiment, the printed circuit board (PCB) forms the center of the pin header. The pin header can further include an overmolded housing that surrounds the PCB, ensuring its integration and protection. Overmolding encloses the PCB with a protective shell, enhancing the durability and reliability of the pin header module through additional mechanical support and protection from environmental factors. Similarly, the PCB can be protected by top and bottom covers that clip around it and are held together by a positive fit.This new feature (housing or covers) offers several advantages, including improved structural integrity of the pin header module, enhanced protection of the printed circuit board from external factors such as moisture, dust, and physical damage, electrical insulation, and potentially better thermal management due to the encapsulation material of the overmolded housing. Using an overmolded housing ensures that the printed circuit board and pins remain securely in the pin header holder, reducing the risk of slippage or damage during handling and operation.

[0021] In another embodiment, the circuit board includes at least one sensor for monitoring the operation of the pin header module. This sensor could be, for example, a temperature sensor or a humidity sensor that monitors the sealing of a closed connector. The sensor's function is to provide real-time data on the operating conditions of the pin header module, thereby improving its functionality and reliability. This allows for the detection of potential problems, such as those related to temperature fluctuations or moisture ingress, which could affect the module's performance and lifespan. By monitoring these parameters, the system can ensure optimal operating conditions and proactively counteract any anomalies, thus improving the overall efficiency and lifespan of the pin header module.

[0022] In designs where the splice element is located inside the pin block holder, the pins may have an oval slot in their center, shaped like an eye or a cat's eye. This design feature allows the two outwardly convex sides of the slot to be elastically compressed. This elastic compressibility ensures that the pin, when mounted in the pin block holder, maintains reliable contact with the splice element. The oval slot in the pins enhances the functionality of the pin block module by ensuring a secure and consistent connection with the splice element. This design allows the pins to adapt to minor positional or pressure variations and maintain a stable electrical connection within the pin block holder.

[0023] It is possible to accommodate spliced ​​and unspliced ​​pins in a single pin block module, i.e., to combine spliced ​​and unspliced ​​pins in one module. This can increase the flexibility and efficiency of modular connectors by reducing the need for separate connectors and additional cable lengths. For this purpose, the pin block module comprises at least three pins. Of these pins, at least two are spliced, meaning they are connected to each other, while at least one pin remains unspliced.

[0024] It is also possible to combine pins with molded splice elements on one side of the pin block module with splice elements and corresponding pins arranged within the pin block carrier, for example to combine the advantages of a highly automated overmolding process and a highly specific through-hole process.

[0025] Some embodiments of the pin block module can be manufactured by inserting pins through the pin block carrier. In such a method, the pin block carrier has pin holes arranged in a desired pattern. Pins can be inserted through the pin block carrier according to a first embodiment using integrally formed splice elements and pins, and according to a third embodiment, the splice element is located within the pin block carrier. The pins can be securely inserted into the pin block carrier in a specific arrangement that is crucial for the proper functioning of the modular connectors. The advantage of this method is that it allows for precise and reliable pin placement.

[0026] Some embodiments of the pin block module can also be manufactured by arranging the pins with at least one splice element according to a desired pattern and by forming at least one part of the pin block carrier around the pins and the at least one splice element.

[0027] Another method for manufacturing a pin block module for use in modular connectors consists of arranging at least two pins with the at least one splice element in a specific desired pattern and then casting at least a portion of the pin block carrier around these arranged pins and the at least one splice element. This method is used as a replacement for the through-hole method in the second embodiment of the pin block module and in addition to the through-hole method in the third embodiment of the pin block.

[0028] The advantage of this method lies in the ability to integrate the pins and splice elements into a single cast structure, which can increase the mechanical stability and reliability of the connector. By arranging the pins in a desired pattern and casting the support block around them, the process allows for precise control over the configuration and orientation of the pins, which is crucial for ensuring proper electrical connections. This approach can also facilitate the use of automated assembly techniques, thereby increasing manufacturing efficiency.

[0029] The pin block module according to the invention can be part of a modular connector. Such a modular connector can comprise a connector housing with at least one seat for a pin block module. The pin block module can be mounted in this at least one seat.

[0030] The term "modular connector" refers to a connector system consisting of interchangeable parts or modules that allow for flexible configuration and application. The "connector housing" is the outer shell or enclosure that accommodates and holds multiple pin block modules. The "seats" within the connector housing are designed to securely hold the pin block modules in place.

[0031] The advantage of this modular connector system lies in its flexibility and adaptability. By allowing different pin block modules to be mounted within the same connector housing, the system can be adapted to various applications and requirements. This modularity can lead to cost savings by reducing the need for multiple different connector designs. It also simplifies maintenance and upgrades, as individual modules can be replaced or upgraded without replacing the entire connector system. Furthermore, the modular design can improve the efficiency of manufacturing and assembly processes because components are standardized for different connector configurations. 4. Brief description of the drawings

[0032] Preferred embodiments of the disclosure are below with reference to the accompanying figures, in which: Fig. 1 shows different types of pens arranged so that they can be stored in a pen holder; Fig. 2 shows an embodiment of a pin block module with pins inserted into a pin block carrier; Fig. Figure 3 shows a schematic representation of the functionality of the integrated splice compared to the state of the art; Fig. Figure 4 shows an embodiment of a pin block module according to a first embodiment; Fig. Figure 5 shows an embodiment of a pin block module according to a second embodiment; Fig. Figure 6 shows an embodiment of a pin block module according to a third embodiment, which shows separate splice elements; Fig. Figure 7 shows the embodiment of a pin block module according to a third embodiment, as in Fig. 6 shown, with the outer protective cover; Fig. Figure 8 shows a clear diagram of a state-of-the-art network; Fig. Figure 9 shows an illustrative diagram of an exemplary network according to the invention. 5. Detailed description of preferred embodiments

[0033] Preferred embodiments of the present disclosure are described in detail below with reference to the figures.

[0034] Fig. Figure 1 shows a plurality of pins 3. The plurality of pins 3 comprises an arrangement of four first pins 31 and four second pins 32, which are in a pin block holder 2 (shown in Fig. 2) are installed. The first and second pins are connected using splice elements 4, which will be described in more detail later. In addition, eighteen third pins 33 are arranged between the first and second pins. The third pins 33 are ordinary pins and are not spliced. The pins 3 are arranged according to a desired pattern.

[0035] The first pins 31 are equipped with retention hooks 311, which facilitate anchoring within the pin block carrier 2. The barbs 311 are shaped to allow an insertion direction 312 when the first pins 31 are inserted into the pin block carrier 2. A splice element 4 in the form of a splice section 41 is integrally formed between the barbs 311 of two adjacent pins 31. Viewed in the insertion direction 312, the splice sections 41 are located at the ends of the respective retaining webs 311. Production tabs 42 are also located at the beginning of the retaining webs 311 on these first pins 31, viewed in the insertion direction 312. However, these production tabs 42 are designed to be removed before the first pins 31 are inserted into the pin block carrier 2. In the arrangement of the first pins 31, four pins are connected by three splice sections 41.

[0036] The second pins 32 are connected by a splice element 4, which is formed by upper and lower splice sections 41 located in the center of the second pins 32. The splice element also forms a retaining contour 321 for adjacent second pins 32. Together, the connecting sections 41 define a through-hole 413, which serves to improve the retention of the second pins 32 when, for example, the pin block support 2 is formed on (or around) the pins. Furthermore, in the arrangement of the second pins 32 shown, four pins 32 are spliced ​​(i.e., connected to each other) in a rectangular configuration.

[0037] Fig. Figure 2 shows a detailed view of a pin block module 1, which includes a pin block carrier 2 and the pins 3 arranged in it. Fig. 1 comprises. On the left side, the pin block support 2 is injection-molded onto the second pins 32. On the right side, the first pins 31 and the third pins 33 are inserted through the pin block support 2 (the insertion naturally occurs after the support has been molded onto the second pins). The pin block support 2 is depicted as a solid structure, with the pins extending from both the top 24 and the bottom (in Fig. (2 not visible) extend. The upper surface is referred to below as the first connection surface 24 and the lower surface as the opposite second connection surface 25. Arrows indicate a possible direction of the current / signal flow 6 (input / output) of the pins 3. Since the second pins 32 are connected in a rectangular configuration, a single signal input at one pin is split into four signal outputs. Thus, the other three pin ends protruding from the first connection surface 24 of the four spliced ​​pins 32 are essentially non-functional and could be cut off. However, it is more cost-effective to simply leave them. Similarly, the four first pins 31 are spliced ​​together. Thus, a signal flow 6 inserted into one pin results in four outputs of the signal flow 6, as indicated by the arrows.With normal, unspliced ​​pins 33, each input of signal flow 6 leads to a single output of signal flow 6 of the same pin.

[0038] Fig. Figure 3 schematically shows the current flow through a pin block carrier 2, 2' and a splice element 4, 4', comparing the prior art on the left with the invention on the right. In the left figure, the current (signal flow 6) is shown flowing first through a pin block carrier 2' and then through a separate splice element 4', which is not part of the pin block carrier 2'. The diagram on the right shows a pin block module 1 according to the invention, in which both the pin block carrier 2 and the splice element 4 are part of the pin block module 1.

[0039] Fig. Figure 4 shows an embodiment of another pin block module 11 with a plurality (a total of 13 pins) of pins 3. The pin block module 11 comprises a pin block carrier 21 having a first connection surface 24 and an opposing second connection surface 25. The pin block module 11 includes four spliced ​​pins 31 extending through the pin block carrier 21. Thus, a signal applied to one of the four spliced ​​pins is split into four signals. Each pin 31 protrudes from both the first connection surface 24 and the second connection surface 25. The pins 31 are inserted through the pin block carrier 21 in the direction indicated by arrow 312. The pins 31 have retaining ridges 311 in their center, which anchor the pins 31 within the pin block carrier 21. The module also includes a splice element 4 with splice sections 41, which connects the four pins 31 together.The splice element 4 is located entirely inside the pin block carrier 21 and is formed integrally with the pins 31. Generally, the splice element 4 is shaped such that the pins 31 can be inserted through the pin block carrier 21 without the splice element 4 protruding from it. Viewed in the insertion direction 312, the splice elements 41 are located at the ends of the barbs 311, so that the length of the barbs 311 can anchor itself in the pin block carrier 21 during insertion. In module 11 of . Fig. 4 also show nine regular pins 33 that are not spliced.

[0040] Fig. Figure 5 shows another embodiment of a pin block module 12, which corresponds to module 11 of Fig. 4 resembles. This pin block module 12 comprises a pin block carrier 22, which holds a total of thirteen pins 3, of which four pins 32 are connected and nine pins 33 are not connected. The pin block module 22 is injection-molded over all pins 3. The module 12 contains a splice element 4 that connects the spliced ​​pins 32. The splice element 4 is located within the pin block carrier 22 and comprises splice sections 41 that define a through-hole 413. The through-hole 413 increases the holding force of the spliced ​​pins 32 during casting. The splice element 4 is formed integrally with the spliced ​​pins 32.

[0041] Fig. Figure 6 shows a printed circuit board 231, which is located within a pin block carrier 23 (in Fig. (as shown in Figure 7) can be arranged. A large number of pins 3 (26 in total) are inserted through the circuit board 231. The pins 3 can be regular pins 33, as used in Fig. Figure 1 is shown as an example. The printed circuit board 231 has conductor tracks 432 which serve as splice elements 4 for the electrical connection (splicing) of the pins 3. In the example shown, the conductor tracks 432 connect three pins 3 in a triangular arrangement.

[0042] Fig. Figure 7 shows a pin block module 13 with a pin block carrier 23, which holds the circuit board 231. Fig. 6 encloses. For this purpose, the pin block carrier 23 includes an overmolded housing 235 that surrounds the printed circuit board 231. The overmolded housing 235 forms the outer surface of the pin block carrier 23 and provides structural integrity and protection for the internal components. The pins 3 protrude through the overmolded housing 235 and enable external connections. The pin block module 13 also includes structural features such as fasteners 236 that facilitate the installation of the module in a housing.

[0043] Fig. Figure 8 shows a state-of-the-art configuration of a network with multiple splice points 51. The network consists of nodes connected by lines representing connections that include one or more wires between the two endpoints, each node representing a possible wire endpoint, such as a connector, a splice, a splice saver, or a ring terminal. The splice points 51 are distributed throughout the network and mark the points where splicing takes place. The splice points are located at various nodes, indicating that splicing is required at multiple locations within the network. The figure shows a complex arrangement with multiple splice points, which, due to the numerous splice points, can present potential inefficiencies or weaknesses and manufacturing hurdles in the network.

[0044] Fig.Figure 9 illustrates the invention, which enables an improved network configuration. In this figure, the network also consists of nodes connected to each other by wires, similar to the prior art. However, the invention introduces an integrated splice saver 53, such as a pin block module 1 of the invention. This splice saver 53 is strategically placed within the network and reduces the number of required splice points 51. The figure shows that the integrated splice saver 53 combines several splice points into a single location, thereby simplifying the network structure. Reducing the number of splice points 51 increases the efficiency and reliability of the network because potential failure points and maintenance requirements are minimized, and manufacturing is simplified.This configuration represents a significant improvement over the state of the art, as it optimizes the splicing process and reduces the complexity of the network. List of reference symbols 1, 11, 12, 13 Pen pad module 2, 21, 22, 23 pencil block holders 2' State-of-the-art pin block holder 231 Circuit board 235 Cases 236 fasteners 24 first connection surface 25 second connection surface 3 pens 31 first pen(s) 311 barbs 312 Insertion direction 32 second pen[s] 321 Holding contour 33 third pen[s] / regular pens 4, 4' splice element 41 Splice section 42 production tabs 432 conductor track 51 Splice point 52 state-of-the-art connectors 53 splice savers 6. Current / signal flow (input / output)

Claims

[1] Pin block module (1, 11, 12, 13) for insertion into a housing of a modular connector, the pin block module (1, 11, 12, 13) comprising • a pin block carrier (2, 21, 22, 23) with a first connecting surface (24) and an opposite second connecting surface (25), • at least two pins (3, 31, 32, 33) extending through the pin block carrier (2, 21, 22, 23) such that each pin (3, 31, 32, 33) protrudes from the first connecting surface (24) and from the second connecting surface (25), characterized by , that the pen pad module (1, 11, 12, 13) further comprises • at least one splice element (4) that connects the at least two pins (3, 31, 32, 33) to each other in order to splice them. [2] Pin block module (1, 11, 12, 13) according to claim 1, wherein the at least one splice element (4) is arranged within the pin block carrier (2, 21, 22, 23). [3] Pin block module (1, 11, 12) according to claim 1 or 2, wherein the at least two pins (3, 31, 32) and the splice element (4) are formed in one piece. [4] Pin block module (1, 11, 13) according to one of the preceding claims, wherein the splice element (4) is designed such that the at least two pins (3, 31, 33) can be sewn into the pin block carrier (2, 21, 23). [5] Pin block module (1, 11) according to one of the preceding claims, wherein the pins have retention barbs (311) in the middle of the pins (3, 31) to anchor the pins (3, 31) in the pin block holder (2, 21). [6] Pin block module (1, 12) according to one of the preceding claims, wherein the pins (3, 32) have a retaining contour (321) in the center of the pins (3, 32) and wherein the splice element (4) comprises at least two splice sections (41), wherein the splice sections (41) define a through hole (413). [7] Pin block module (1, 13) according to one of the preceding claims, wherein at least one splice element (4) is a splice element (432) separate from the pins (3, 33) and arranged within the pin block holder (2, 23). [8] Pin block module (1, 13) according to claim 7, wherein the separate splice element (432) comprises a conductor track (432) which is part of a printed circuit board (231) which is arranged within the pin block carrier (2, 23). [9] Pin block module (1, 13) according to claim 8, wherein the conductor track (432) of the separate splice element (432) directly connects at least two non-adjacent pins (3, 33) without connecting the intermediate pin(s) (3, 33) between the two non-adjacent pins (3, 33). [10] Pin block module (1, 13) according to claim 8 or 9, wherein the printed circuit board (231) forms the center of the pin block carrier (2, 23) and wherein the pin block carrier (2, 23) further comprises an overmolded housing (235) or an upper and a lower cover, which are held together by positive locking and surround the printed circuit board (231). [11] Pin block module (1, 13) according to one of claims 8 to 10, wherein the printed circuit board (231) has at least one sensor for monitoring the operation of the pin block module (1, 13), such as a temperature sensor. [12] Pin block module (1, 11, 12, 13) according to one of the preceding claims, wherein the pin block comprises at least three pins (3, 31, 32, 33), wherein at least two pins (3, 31, 32, 33) are spliced ​​and wherein at least one pin is not spliced. [13] Modular connector comprising a connector housing with at least one seat for a pin block module (1, 11, 12, 13) and at least one pin block module (1, 11, 12, 13) according to any one of the preceding claims 1 to 12, which is mounted in the at least one seat.

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