ELECTRONICS MODULE WITH INTEGRATED PCB MOUNTING FOR CONTACTING AT LEAST ONE WIRE WITH A CIRCUIT BOARD ATTACHABLE IN THE PCB MOUNTING, AND ASSOCIATED METHOD

Description

[0001] The invention relates to an electronic module with an integrated circuit board receptacle for contacting at least one wire with a circuit board that can be arranged in the circuit board receptacle, and to an associated method for contacting at least one wire with a circuit board that can be arranged in the circuit board receptacle of the electronic module.

[0002] In principle, a large number of devices and methods for contacting components or wires with printed circuit boards or the contacts provided for this purpose on the printed circuit boards are already known from the prior art.

[0003] In addition to the generally known soldering of components to the contacts of the circuit board, connection elements for soldering or soldering to circuit boards are known, for example from DE 10 2016 212 631 A1, in which a component or a wire can subsequently be connected to the circuit board via the connection element. However, this has the disadvantage that the wire can only be arranged on the resulting electronic module after the circuit board has been equipped with the connection elements and these have been soldered to the contacts of the circuit board.

[0004] Furthermore, for example, DE 20 2017 105 830 U1 discloses a system by which wires in the form of stranded wires are soldered onto a flexible printed circuit board using a bar soldering process. This system also requires a fixed sequence, as the printed circuit board must first be positioned in a tool before the wires can be placed, and the wires are then connected to the contacts of the printed circuit board using bar soldering.

[0005] Specifically related to coils or wires wound into coils, DE 20 2013 010 951 U1 also teaches a printed circuit board assembly in which contact elements must be inserted into the circuit board and permanently contacted with it before the coil wires can be inserted into the contact elements. Here, too, the assembly sequence is fixed accordingly, especially since, in addition to the contact surfaces of the circuit boards and the wires, additional contact elements and their assembly are necessary to enable contact.

[0006] DE 101 34 562 A1 discloses a system for electrically contacting and mechanically fastening printed circuit boards, comprising: an insulation displacement element for attachment to the underside of a printed circuit board, a fastening element on the printed circuit board, a carrier, with respect to which a conductor wire is fixed in such a way that, during the mechanical fastening of the printed circuit board to the carrier by means of the circuit board-side fastening element, the conductor wire can simultaneously be directly contacted by the insulation displacement element on the underside of the printed circuit board.

[0007] The invention is therefore based on the object of overcoming the aforementioned disadvantages and providing an electronic module by means of which wires and in particular coil wires can be contacted in a simple and cost-effective manner with a printed circuit board or the contact surfaces of the printed circuit board provided for this purpose.

[0008] This problem is solved by the combination of features according to patent claim 1.

[0009] According to the invention, an electronic module with an integrated printed circuit board receptacle is therefore proposed for contacting at least one wire with a printed circuit board that can be arranged in the printed circuit board receptacle and, for example, pushed into the printed circuit board receptacle. The printed circuit board receptacle has at least one guide element which is designed to guide the printed circuit board that can be arranged in the printed circuit board receptacle into a predetermined end position and, in particular, to hold it in the end position. It is provided that the printed circuit board is arranged in a predetermined plane in the end position and that contact surfaces provided on the printed circuit board are in a predetermined mounting position. In addition, the printed circuit board receptacle has two wire receptacles for each wire that is to be contacted with the printed circuit board, i.e. a pair of wire receptacles for each wire, the two wire receptacles orthe wire receptacles of the pair lie opposite one another on the circuit board receptacle and are designed to receive and further preferably fix a wire which runs straight and freely between the two wire receptacles and is preferably tensioned with a predetermined pre-tension. In this case, freely running is understood in particular to mean that the wire, as long as it has not yet made contact with the contact surface, does not touch any other elements running between the associated wire receptacles and in particular does not touch a circuit board already arranged in the circuit board receptacle. According to the invention, it is also provided that the two wire receptacles, i.e. the pair of wire receptacles, are further designed to hold at least one wire section of the wire running straight between the two wire receptacles at a predetermined distance from the mounting position orthe associated contact surface of a circuit board already arranged in the circuit board holder and further in particular to be held parallel to the contact surface or the plane, so that the wire can be pressed from this previously known position with the wire section by an assembly tool against the contact surface in the previously known assembly position and can be connected to the contact surface.

[0010] In particular, the electronic module or the circuit board holder is not a tool or a template which is removed after contacting, but preferably an integral component of an object to be manufactured and which accordingly has the electronic module.

[0011] For the at least one guide element, it is preferably provided that it is arranged and designed to guide the circuit board into the end position independently of the at least one wire, so that the circuit board can be guided from the outside into the guide device and in the guide device into the end position, regardless of whether the wire receptacles are empty or a wire is already arranged in them.

[0012] Accordingly, it is preferably the case for the wire receptacles that the wire can be arranged in the wire receptacles independently of the circuit board, so that the at least one wire can be arranged in or on the circuit board before or after the circuit board assembly, ie before or after the circuit board is arranged in the circuit board receptacle.

[0013] Although the circuit board and the at least one wire can each be considered separate from the electronic module, the circuit board and / or the at least one wire can also be considered as a component belonging to the electronic module.

[0014] Preferably, the circuit board receptacle has four wire receptacles or two pairs of wire receptacles, so that two wires can each be contacted with a contact surface provided for this purpose on the circuit board.

[0015] The two wires can also be understood in particular as the two opposite and thus connected wire ends of a wire wound, for example, into a coil. Accordingly, two wires can be connected to each other.

[0016] Furthermore, the entire electronic module is preferably made of one piece, in particular in one piece, and more preferably made of plastic. For example, the electronic module can be manufactured using a plastic injection molding process.

[0017] An advantageous development provides that the circuit board holder has two opposing guide rails as guide elements, between which the circuit board can be inserted in the plane. The guide rails can be connected to one another on one side of the plane and separated from one another on the opposite, second side of the plane, so that the circuit board remains fully accessible from the second side.

[0018] Preferably, it is provided that one wire receptacle of the two wire receptacles or of the pair of wire receptacles is assigned to one guide rail of the two guide rails, so that the wire can be arranged in the wire receptacles running from a first guide rail to a second guide rail.

[0019] As an alternative to the two opposing guide rails, it can alternatively be provided that the circuit board holder has at least one guide pin extending orthogonally to the plane as a guide element, along which the circuit board can be pushed into the plane.

[0020] Two or more guide pins arranged offset from one another can also be provided. In particular, if only one guide pin is provided, it can be asymmetrical or rectangular, or it can interact with other guide elements to ensure the arrangement of the circuit board in the final position with a predetermined orientation, in which the at least one contact surface is located in its respective mounting position.

[0021] With regard to the printed circuit board, when using guide pins, it should be noted that it has recesses or openings corresponding to at least one guide pin.

[0022] Furthermore, in one variant, the electronic module provides that the circuit board holder has at least one end stop extending orthogonally to the plane and determining the end position, against which the circuit board can be pushed. If guide rails are provided, the end stop can provide a stop surface extending orthogonally to the plane. In the case of guide pins, the end stop preferably provides a stop surface extending parallel to the plane.

[0023] In order to be able to easily bring the wire(s) into their predetermined position, a further development preferably provides that at least some of the wire receptacles, and in particular all of the wire receptacles, are each designed as tapered grooves, thus acting in particular as funnels, into which the respective wire can be inserted from an open side of the grooves for centering and positioning the wire. Accordingly, the groove can have a V-shaped cross-section.

[0024] In particular, in the tapered end section of the groove, fixing means, such as clamping blades or locking hooks extending into the groove, can be provided to secure a wire inserted into the groove and brought to the end section. Such fixing means can also be provided only for one wire receptacle of a pair, and preferably for the wire receptacle located closer to a free wire end of the wire.

[0025] In addition to slots open on one side, which can be tapered as described, wire receptacles designed as cutouts are also possible. However, these have the disadvantage that, unlike a slot, they have a closed contour, so the wire must be threaded into the respective cutouts. Depending on the structural design of the electronic module, this may be necessary or advisable.

[0026] The design of the wire receptacles can be mixed. For example, a first wire receptacle of a pair can be designed as a groove, and a second wire receptacle of the pair can be designed as an opening.

[0027] Some of the wire receptacles and in particular all of the wire receptacles can extend from a side of the circuit board receptacle facing away from the plane to the plane without intersecting the plane, so that the wire running between the wire receptacles is arranged or can be arranged on a first side of the plane.

[0028] Alternatively, some of the wire receptacles and in particular all of the wire receptacles can extend from a side of the circuit board receptacle facing away from the plane beyond the plane and intersect the plane, so that the wire running between the wire receptacles is arranged on a second side of the plane which is opposite to the first side with respect to the plane.

[0029] Furthermore, it can also be provided that a first part of the wire receptacles extends to the plane without intersecting the plane, and a second part of the wire receptacles extends beyond the plane and intersects the plane. The first part of the wire receptacles is arranged accordingly on the first side and the second part of the wire receptacles on the second side, wherein the wire receptacles of a pair are each arranged and configured such that the wire passing through them extends parallel to the plane and at the predetermined distance from the mounting position.

[0030] Also, a first part of the wire receptacles can extend from a first side to the plane without intersecting the plane and a second part of the wire receptacles can extend from a second side, which is opposite the first side with respect to the plane, to the plane without intersecting the plane, so that wires can be arranged on both sides of the plane or the circuit board and can be connected to the circuit board.

[0031] In order to be able to fix the free end of a wire to the electronic module or to the circuit board receptacle, the circuit board receptacle can have a fixing element, in particular for each wire to be contacted with the circuit board, in particular designed as a winding pin, to which a free end of the wire running straight between the two wire receptacles can be fixed. The wire can accordingly be wound several times with its free end around the winding pin and thereby tensioned and fixed between the wire receptacles, in particular with the predetermined pretension. Furthermore, the fixing element can also be designed, for example, as a clamping mechanism, by means of which the wire can be tensioned between the associated wire receptacles and clamped to the fixing element.

[0032] The predetermined distance of the wire to the mounting position is preferably less than 5 mm, in particular less than 1 mm and more particularly equal to or less than 0.5 mm. In this case, the distance is selected in such a way that the wire can be pressed against the associated contact surface in a tensioned manner. If the wire has already been arranged between the associated wire receptacles in a tensioned manner, for example by pre-tensioning, the wire is stretched accordingly when pressed against the contact surface or is subjected to a higher tension. It can therefore also be provided that the wire or the course of the wire between the wire receptacles is essentially straight but, at least before being connected to the contact surface, is not yet tensioned to its maximum load-bearing capacity, so that deflection from this course towards the contact surface is possible.

[0033] Preferably, the electronic module further comprises a coil winding body around which a coil wound from the at least one wire can be arranged or wound.

[0034] As previously mentioned, the electronic module may be one-piece, so that the coil winding body may be formed integrally with the circuit board receptacle.

[0035] It should also be noted that the contact surfaces of the circuit board do not have to be provided on a common side of the circuit board. For example, at least one first contact surface can be arranged on a first side and at least one second contact surface on an opposite side.

[0036] With respect to the predetermined plane, the wires associated with the at least one first contact surface can be arranged on a first side of the plane, and the wires associated with the at least one second contact surface can be arranged on a second side of the plane. The wire receptacles associated with the wires are designed and arranged to hold the respective wire on the first side of the plane or on the second side of the plane at the predetermined distance from the respective associated contact surface.

[0037] In addition to the electronic module itself, a further aspect of the invention relates to a method for contacting at least one wire with a printed circuit board that can be arranged in the printed circuit board receptacle of the electronic module according to the invention. The method comprises the steps a. Arranging the circuit board in the circuit board receptacle such that the contact surface provided for each wire on the circuit board is in the mounting position; b. Arranging the at least one wire in the respective or associated wire receptacles such that the wire runs straight between the two wire receptacles and has the predetermined distance from the mounting position; c. Contacting the at least one wire with the respective contact surface by pressing the wire against the contact surface and electrically contacting the contact surface, in particular by soldering and further in particular using the bar soldering method.

[0038] It is intended that the steps can be carried out in the order a, b, c as well as in the order b, a, c.

[0039] For the bar soldering process, in particular an assembly tool designed as a stamp is used, which can be moved orthogonally or parallel to the plane of the circuit board and can be guided to the contact surface by pressing at least one wire against the contact surface belonging to the respective wire.

[0040] As an alternative to contacting by soldering or hot-bar soldering, the wire can also be connected to the contact surface, for example, by bonding or laser soldering, although this may still require a stamp that presses the wire against the contact surface but does not actively contribute to the permanent contact of the wire with the contact surface.

[0041] The features disclosed above can be combined as desired, as long as this is technically possible and they do not contradict each other.

[0042] Other advantageous developments of the invention are characterized in the subclaims or are presented in more detail below, together with the description of the preferred embodiment of the invention, with reference to the figures. They show: Fig. 1 shows an electronic module with a circuit board and wires arranged thereon before contacting, in a side view; Fig. 2 shows the electronic module with a circuit board and wires arranged thereon after contacting, in a side view; Fig. 3 shows the electronic module without a circuit board and wires arranged thereon, in a side view; Fig. 4 shows the electronic module with a circuit board and wires arranged thereon, in a top view; Fig. 5 shows the electronic module with a circuit board and wires arranged thereon, in a sectional view; Fig. 6 shows an alternative electronic module with a circuit board and wires arranged thereon, in a sectional view; Fig. 7 shows an alternative electronic module with a circuit board and wires arranged thereon, in a sectional view.

[0043] The figures are schematic examples. Identical reference numerals in the figures indicate identical functional and / or structural features.

[0044] In the Figures 1 to 5 an electronic module 1 with integrated circuit board holder 10 is shown, wherein in the Figures 1, 2 and 4 and 5, both the circuit board 4 and the wires 2, 3 are shown. The circuit board 4 is shown arranged in or on the circuit board holder 10. The wires 2, 3 are intended, as particularly shown in Figure 2 visible, contacted with the contact surfaces 5, 6 of the circuit board 4.

[0045] In the variant shown in the figures, the circuit board 4 has two contact surfaces 5, 6, wherein a wire 2, 3 is to be contacted with one of the contact surfaces 5, 6. The two wires 2, 3 are the end sections, ie the wire ends, of a single wire wound into the coil 8 and arranged on the coil winding body 18, so that the wires 2, 3 represent the wire ends of this one wire and are connected to one another via the section wound into the coil or are formed in one piece and integrally with one another.

[0046] One of the advantages of the proposed electronic module 1 is that the circuit board 4 can be arranged independently of the wires 2, 3 in the circuit board receptacle 10 and the wires 2, 3 can in turn be arranged independently of the circuit board 4 in the circuit board receptacle 10.

[0047] To accommodate the printed circuit board 4, the printed circuit board holder 10 has two opposing guide rails 11, 12, which are connected to one another on one side via a web or other stiffening element 19. The guide rails 11, 12 define a plane E in which the printed circuit board 4 can be inserted into the guide rails 11, 12 and into an end position in which the printed circuit board 4 rests against an end stop 15, as shown in the figures.

[0048] If the circuit board 4 is in this final position, the contact surfaces 5, 6 are arranged in a respective predetermined mounting position in which the contact surfaces 5, 6 can be contacted with a respective wire 2, 3 at a later time.

[0049] To accommodate the wires 2, 3, the circuit board receptacle 10 has a pair of wire receptacles or two wire receptacles 13A, 13B, 14A, 14B for each wire, so that a first pair of wire receptacles or two wire receptacles 13A, 13B are assigned to a first wire 2 and a second pair of wire receptacles or two wire receptacles 14A, 14B are assigned to a second wire 3. The two wire receptacles 13A, 13B and 14A, 14B of a pair are arranged opposite one another on the circuit board receptacle 10, so that a wire leading from wire receptacle 13A or 14A to wire receptacle 13B or 14B runs essentially parallel to plane E.

[0050] The wire receptacles 13A, 13B, 14A, 14B are generally designed to hold the respective wire 2, 3 at a predetermined distance A from the mounting position, i.e., at a predetermined distance A from the respective contact surface 5, 6. Since the distance of the contact surfaces 5, 6 to the plane E is known, the distance A can also be generally defined as the distance between the wires 2, 3 and the plane E, in which case the thicknesses of the circuit board 4 and the contact pads providing the contact surfaces 5, 6 must be taken into account.

[0051] In order to be able to position the wires 2, 3 independently of the circuit board 4 and in a simple manner, the wire receptacles 13A, 13B, 14A, 14B are designed as V-shaped tapered grooves, as is particularly the case in Figure 5is visible. Due to the illustrated shape of the wire receptacles 13A, 13B, 14A, 14B, the wires 2, 3 can be easily inserted from the open side of the groove and centered toward the tapered side.

[0052] If no fixation is provided by the wire receptacles 13A, 13B, 14A, 14B themselves, the electronic module 1 can have a fixing element or, as shown, a fixing element 16, 17 for each wire 2, 3, around which the wires 2, 3 or their free ends 5 can be wound and thus fixed. Alternatively, a single fixing element could be provided for both wires 2, 3, which could, for example, be arranged between the wire receptacles 13B, 14B.

[0053] Regardless of whether the circuit board 4 was first arranged in the circuit board receptacle 10 or whether the wires 2, 3 were first arranged in the circuit board receptacle 10, the actual contacting of the wires 2, 3 with the respective contact surface 5, 6 can then take place.

[0054] For this purpose, a stamp designed and in Figure 2 illustrated assembly tool 7 is used, which presses the wires 2, 3 individually against the respective associated contact surface 5, 6 and solders them to the contact surface 5, 6 preferably by soldering and more preferably by bar soldering, so that the wires 2, 3 are permanently electrically contacted with the respective contact surface 5, 6.

[0055] The wire holders 13A, 13B, 14A, 14B do not necessarily have to be arranged as shown in Figure 5 shown extending from a common side towards the plane E without intersecting it.

[0056] Further variants are also available in the Figures 6 and 7 presented, with additional training opportunities available. Figures 5 to 7 The views shown are sections through the electronic module 1 according to the Figure 1 drawn section line BB.

[0057] For example, the wire receptacles 13A, 13B, 14A, 14B can extend from a free side of the printed circuit board receptacle 10, ie not covered by the stiffening element 19, beyond the plane E and behind the plane E, as shown in Figure 6 is shown.

[0058] Alternatively, the wire receptacles 13A, 13B, 14A, 14B can be located on the side of the printed circuit board receptacle 10 covered by the stiffening element 19, as in Figure 7 , extend beyond the plane E behind the plane E, wherein corresponding recesses are provided in the stiffening element 19 through which the wires 2, 3 and optionally the assembly tool 7 can be guided.

[0059] Furthermore, the wire receptacles 13A, 13B, 14A, 14B of a pair or different pairs of wire receptacles 13A, 13B, 14A, 14B can also extend from different sides to the plane E or beyond the plane E, which, however, is not shown.

Claims

1. An electronic module (1) with an integrated circuit board holder (10) for contacting at least one wire (2, 3) with a circuit board (4) which can be arranged in the circuit board holder (10), wherein the circuit board holder (10) has at least one guide element (11, 12) which is formed to guide the circuit board (4) which can be arranged in the circuit board holder to a predetermined end position in which the circuit board (4) is arranged in a predetermined plane (E) and contact surfaces (5, 6) provided on the circuit board (4) are in a predetermined mounting position, wherein the circuit board holder (10) has two wire holders (13A, 13B, 14A, 14B) per wire (2, 3) to be contacted with the circuit board (4), which are opposite to one another on the circuit board holder (10) and are formed to hold a wire (2, 3) running straight and freely between the two wire holders (13A, 13B, 14A, 14B), wherein the two wire holders (13A, 13B, 14A, 14B) are further formed to keep at least one wire section of the wire (2, 3) running straight between the two wire holders (13A, 13B, 14A, 14B) at a predetermined distance (A) to the mounting position so that the wire (2, 3) can be pressed against the respective contact surface (5, 6) with the wire section by a pressing tool (7) and can be connected with the contact surface (5, 6).

2. The electronic module according to claim 1, wherein the circuit board holder (10) has two guide rails (11, 12) opposite to one another as guide elements (11, 12) between which the circuit board (4) can be inserted in the plate (E).

3. The electronic module according to claim 2, wherein a respective wire holder (13A, 13B, 14A, 14B) of the two wire holders (13A, 13B, 14A, 14B) is respectively assigned to a guide rail (11, 12) of the two guide rails (11, 12).

4. The electronic module according to claim 1, wherein the circuit board holder (10) has at least one guide pin as a guide element extending orthogonally to the plane (E) and along which the circuit board (4) can be slid into the plane (E).

5. The electronic module according to any one of the preceding claims, wherein the circuit board holder (10) has at least one end stop (15) extending orthogonally to the plane (E) and determining the end position, against which the circuit board (4) can be slid.

6. The electronic module according to any one of the preceding claims, wherein at least a part of the wire holders (13A, 13B, 14A, 14B) and in particular all wire holders (13A, 13B, 14A, 14B) are respectively formed as tapering grooves into which the respective wire (2, 3) can be inserted from an opened side of the grooves for centring and positioning the wire (2, 3).

7. The electronic module according to any one of the preceding claims, wherein a part of the wire holders (13A, 13B, 14A, 14B) and in particular all wire holders (13A, 13B, 14A, 14B) extend from a side of the circuit board holder (10) facing away from the plane (E) up to the plane (E) without intersecting the plane (E) so that the wire (2, 3) running between the wire holders (13A, 13B, 14A, 14B) is arranged on a first side of the plane (E), and / or wherein a part of the wire holders (13A, 13B, 14A, 14B) and in particular all wire holders (13A, 13B, 14A, 14B) extend from a side of the circuit board holder (10) facing away from the plane (E) beyond the plane (E) and intersect the plane (E) so that the wire (2, 3) running between the wire holders (13A, 13B, 14A, 14B) is arranged on a second side of the plane (E).

8. The electronic module according to any one of the preceding claims, wherein the circuit board holder (10) in particular has a fixation element (16, 17) in particular formed as a winding pin (16, 17) per wire (2, 3) to be contacted with the circuit board (4), on which an in particular free end (5) of the wire (2, 3) running straight between the two wire holders (13A, 13B, 14A, 14B) can be fixed.

9. The electronic module according to any one of the preceding claims, wherein the predetermined distance (A) of the wire (2, 3) to the mounting position is less than 5 mm, in particular less than 1 mm and further in particular equal to or less than 0.5 mm.

10. The electronic module according to any one of the preceding claims, further having a coil winding body (18) about which a coil (8) wound from the at least one wire (2, 3) can be arranged or wound.

11. A method for contacting at least one wire (2, 3) with a circuit board (4) which can be arranged in the circuit board holder (10) of the electronic module (1) according to any one of the preceding claims, comprising the steps of a. arranging the circuit board (4) in the circuit board holder (10) so that the contact surface (5, 6) provided on the circuit board (4) per wire (2, 3) is in the mounting position; b. arranging the at least one wire (2, 3) in the respective wire holders (13A, 13B, 14A, 14B) so that the wire (2, 3) runs straight between the two wire holders (13A, 13B, 14A, 14B) and has the predetermined distance (A) to the mounting position; c. contacting the at least one wire (2, 3) with the respective contact surface (5, 6) by pressing the wire (2, 3) against the contact surface (5, 6) and electrical contacting with the contact surface (5, 6), in particular through soldering and further in particular with the hot bar soldering method; characterised in that the steps can be performed both in the order a, b, c and b, a, c.