Housing for an electronic control unit and method for manufacturing the same

Abstract

A housing assembly for electronic circuitry including an electronic control unit (ECU) is a generally rectangular, low profile device including a housing, a lid closing an open end of the housing, and a printed circuit board disposed within the housing. The housing includes input and output electrical connectors formed on opposite ends of the housing. The output electrical connector includes conductive pins having an irregular shape and partially recessed in the housing such that each pin has zero degrees of freedom of movement relative to the housing.

Description

Technical Field

[0001] Background An electronic control unit (ECU) can be used, for example, to control components of a motor assembly used in a vehicle to set the position of vehicle elements such as windows, mirrors, seats and / or doors. The ECU includes a housing and a printed circuit board (PCB) assembled within this housing. The PCB can support control devices, computer memory, embedded software, communication devices, electronic circuits and other auxiliary devices. The ECU housing may include one or more electrical connectors. The connector may be configured to house an electrical harness that connects the ECU to an external device such as a vehicle engine, a motor assembly or another device. Within the connector, pins can be used to provide an electrical connection between the harness and the PCB. In some conventional plastic ECU housings, warping of the housing may occur during manufacturing or in some use environments, and this warping can result in an unstable pin arrangement within the electrical connector. Further, due to environmental conditions during vehicle use, such as vibration, shock, humidity, corrosion, high separation force, etc., pin instability with respect to the ECU housing can occur. Since pin instability with respect to the ECU housing can cause problems with the electrical connection to the ECU, it is desirable to provide an ECU housing in which the pins are stably held and the reliability of the electrical connection is improved.

[0002] Summary In some embodiments, the ECU is an assembly including an ECU housing and a PCB disposed within this ECU housing. The PCB supports a control device and electronic devices and structures that support the functions of this control device. The ECU housing includes a container, a lid that closes the open end of the container, and an electrical connector that enables the connection of the ECU to an external device. The connector includes a plurality of pins, with the first end of each pin existing within the container to form an electrical connection with a terminal of the PCB and the second end of each pin being disposed outside the container and surrounded by a protective flange, embedded in the side wall of the container. As used herein, the term "embedded" refers to being closely surrounded by the plastic material of the housing and covered within the plastic material of the housing. This can be achieved, for example, by manufacturing a housing with pins at a predetermined position in an overmolding process. Further, the pins are formed to cooperate with the surrounding housing material such that the pins are firmly positioned with respect to the housing side wall. In particular, the pins are supported within the housing side wall such that they have zero degrees of freedom of movement with respect to the housing side wall. Thereby, a stable ECU housing with improved reliability of the electrical connection is provided. Advantageously, the advantage of using the overmolding process is that the number of manufacturing steps during the assembly of the ECU housing is reduced, thereby reducing the manufacturing cost compared to some conventional ECU housings.

[0003] In some embodiments, the housing assembly includes a housing having a container and a lid. The container includes a base and a side wall projecting from the base in a direction perpendicular to the base. The first end of the side wall is connected to the base, and the second end of the side wall defines a container opening. The lid is shaped and dimensioned to close the container opening. Further, the housing assembly includes conductive pins extending through a first portion of the side wall. The first end of each pin includes a first electrical connection portion. The second end of each pin includes a second electrical connection portion. Each pin is partially embedded in the container such that the first electrical connection portion is exposed and disposed outside the housing, and the second electrical connection portion is exposed and disposed inside the housing. Further, the portion of the pin embedded in the container is irregularly shaped and engages the container such that each pin has zero degrees of freedom of movement with respect to the container.

[0004] In some embodiments, the first electrical connection portion has a female electrical connection configuration.

[0005] In some embodiments, the container includes an inner retaining portion adjacent to the first portion of the side wall and projecting inwardly from the inner surface of the side wall, and an outer support block adjacent to the first portion of the side wall and projecting outwardly from the outer surface of the side wall. Each pin extends through the first portion of the side wall, the inner retaining portion, and the outer support block.

[0006] In some embodiments, the outer support block is surrounded by a tubular shroud.

[0007] In some embodiments, the container includes a shroud projecting outwardly from the first portion of the side wall. The shroud surrounds the first end of the pin and defines an outer opening configured to engage a corresponding mating connector.

[0008] In some embodiments, the housing has a height dimension, a length dimension, and a width dimension. The height dimension corresponds to the distance along the Z-axis line between the outer surface of the base and the outer surface of the lid. The length dimension corresponds to the distance along the Y-axis line between the outer surface of the first portion of the side wall and the outer surface of the second portion of the side wall that is parallel to the first portion of the side wall and spaced apart from the first portion of the side wall. The width dimension corresponds to the distance along the X-axis line between the third portion of the side wall and the fourth portion of the side wall, and the third portion and the fourth portion of the side wall are perpendicular to the first portion and the second portion of the side wall and are spaced apart from each other. The X-axis line, the Y-axis line, and the Z-axis line are perpendicular to each other, and the container is configured to prevent the axial movement of each pin with respect to the X-axis line, the Y-axis line, and the Z-axis line, and to prevent the rotational movement of each pin about the X-axis line, the Y-axis line, and the Z-axis line.

[0009] In some embodiments, each pin has a first pair of opposing flat surfaces that are perpendicular to the X-axis line, a second pair of opposing flat surfaces that are perpendicular to the Y-axis line, and a third pair of opposing flat surfaces that are opposed to the Z-axis line. Each of the first pair, the second pair, and the third pair of opposing flat surfaces abuts against the container, whereby the container is configured to prevent the axial movement of each pin in the X-direction, the Y-direction, and the Z-direction, and to prevent the rotational movement of each pin about the X-axis line, the Y-axis line, and the Z-axis line.

[0010] In some embodiments, the housing assembly includes a printed circuit board disposed within the housing. The printed circuit board includes electrical connection plugs, and the second electrical connection portions of each pin are electrically connected to a corresponding one of the electrical connection plugs.

[0011] In some embodiments, the portion of each pin embedded in the container has an L-shaped outer profile.

[0012] In some embodiments, each pin has a through-opening, and the material used to form the container fills the through-opening.

[0013] In some embodiments, each pin has a flange protruding from the surface of the respective pin.

[0014] In some embodiments, at least some of the pins have an integral spring element protruding from the side surface of the respective pin.

[0015] In some embodiments, the pins are fixed in position relative to the container by an overmolding manufacturing process.

[0016] In some aspects, the housing assembly has a housing having a container and a lid. The container includes a base and a sidewall protruding from the base in a direction perpendicular to the base. A first end of the sidewall is connected to the base, and a second end of the sidewall defines a container opening. The lid is shaped and dimensioned to close the container opening. Further, the housing assembly includes pins extending through a first portion of the sidewall. Each pin includes a first end including a female-type first electrical connection portion and a second end including a second electrical connection portion. Each pin includes a longitudinal portion extending in a first direction perpendicular to the first portion of the sidewall. The longitudinal portion includes the first electrical connection portion, and the first electrical connection portion is oriented to form an electrical connection in a direction parallel to the first direction. Each pin includes a lateral portion extending in a second direction perpendicular to the longitudinal axis and the surface of the base facing the lid. The lateral portion includes the second electrical connection portion. The second electrical connection portion is oriented to form an electrical connection in a direction parallel to the second direction. Each pin is partially embedded in the container such that the first electrical connection portion is exposed and disposed outside the housing, the second electrical connection portion is exposed and disposed inside the housing, and the embedded portion of the pin engages the container such that the pin has zero degrees of freedom of movement relative to the container.

[0017] In some aspects, a method of manufacturing a housing assembly including a housing and pins protruding from the housing is described. The method includes providing conductive pins. Each pin includes a first end having a female-type first electrical connection portion, a second end on the opposite side of the first end having a second electrical connection portion, and an intermediate portion disposed between the first end and the second end. The intermediate portion has an elbow shape such that the first end extends along a first axis and the second end extends along a second axis perpendicular to the first axis. The method includes engaging the portion of the pin embedded in the housing with the housing such that the first electrical connection portion is disposed outside the housing, the second electrical connection portion is disposed inside the housing, and the pin has zero degrees of freedom of movement with respect to the housing, and forming the housing around the pins such that each pin is partially embedded in a portion of the housing.

[0018] In some embodiments, the step of forming the housing includes an overmolding process in which the pins are partially embedded.

[0019] In some embodiments, the step of forming the housing includes forming a container having a base and a side wall protruding from the base in a direction perpendicular to the base. A first end of the side wall is connected to the base, and a second end of the side wall defines a container opening.

[0020] In some embodiments, the step of providing the conductive pins includes arranging the pins in an array in which each pin is spaced from adjacent pins in the array and parallel to adjacent pins in the array, and the step of providing the conductive pins is performed before the step of forming the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0021]

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[0022] Detailed Description Referring to FIGS. 1 to 6, the motor assembly 1 includes an electric motor unit 2 and an ECU 20. The electric motor unit 2 includes an actuator 3 driven by a gear set (not shown) housed in a gear housing 4. The electric motor unit 2 is powered by an electrical signal received via a motor unit electrical connector 6 supported on the actuator 3, and the electric motor unit 2 may be assembled to the vehicle structure using an assembly plate 5. The ECU 20 includes an ECU housing 21 and a PCB 120. The PCB 120 is disposed within the ECU housing 21 and is a rigid and multi-layered electrical insulation material sheet that supports one or more control device processors (not shown) utilized to modulate an electrical signal output via an output connector 80. The PCB 120 supports electronic devices such as computer memory, embedded software, communication devices, electrolytic capacitors, power components and / or other auxiliary devices. The communication device may include a wireless transmitter, a wireless receiver or a wireless transceiver and is operable to provide wireless data communication between the ECU 20 and one or more external devices such as a local interconnect network (LIN) hub. The PCB 120 also includes conductive tracks (not shown) used to electrically connect electronic components to each other and / or to electrically connect the electronic devices and structures of the PCB 120 to an external device via a connection plug 125 that enables such connection.

[0023] The ECU housing 21 is separated from the housing of the electric motor unit 2 and includes an ECU output connector 80 and an ECU input connector 180. In the illustrated embodiment, the ECU output connector 80 and the ECU input connector 180 each include conductive pins 86, 186 and surrounding shrouds 81, 181, and the shrouds 81, 181 are suitable for connecting to existing vehicle electrical connectors and forming an electrical connection therewith. Details regarding the structure of the input connector 180 and the output connector 80 will be described in detail below.

[0024] The ECU 20 receives power and data via the ECU input connector 180. The ECU input connector 180 is arranged on the side of the ECU housing 21 opposite to the ECU output connector 80 and may be configured to receive power and data from the LIN. The data may have sensor data from sensors, control data or communication data from a processor that communicates data with the LIN. Another configuration can use another data transmission by the ECU input connector 180.

[0025] The ECU 20 is configured to operate as an intermediary between the conventional power source of the vehicle and the electric motor unit 2 by being directly connected to the electric motor unit 2 via a detachable electrical connection between the ECU output connector 80 and the motor unit electrical connector 6. The housing 21 of the ECU 20 has a flat design that is advantageous for a direct coupling to the electric motor unit 2, although in another embodiment, an adapter or connector cable can be utilized. By directly coupling the ECU 20 to the electric motor unit 2, advantageously, the combined motor assembly can be accommodated together within the vehicle, such as behind a seat, console or panel. Further, by directly coupling the ECU 20 to the electric motor unit 2, the electromagnetic compatibility (EMC) of the device can be improved by minimizing the length of the electrical lead wires that couple the ECU 20 and the electric motor unit 2. Minimizing the length of the electrical lead wires can optimize the EMC of the system by minimizing the parts of the system that are susceptible to electromagnetic interference (EMI) from the environment or another external source.

[0026] The ECU 20 may advantageously enable the incorporation of desired control functions, such as automatic control and user control, into a vehicle equipped with an existing conventional electric motor. Thereby, an electric motor such as the electric motor unit 2 can be effectively retrofitted into a modular smart motor via the ECU 20. Since both the output connector 80 and the input connector 180 can be detachably connected, it is possible to reverse the coupling to return the vehicle to its original configuration or to enable the replacement, repair, or upgrade of control components.

[0027] Referring to FIGS. 3 to 9, the ECU housing 21 is a flat device that is generally rectangular. The ECU housing 21 is an assembly that includes a container 22 and a lid 30 that closes the open end 28 of the container 22.

[0028] The lid 30 of the ECU housing 21 is shaped and dimensioned to close the open end 28 of the container. In the illustrated embodiment where the container 22 has an open end 28 of a rectangular container, the lid 30 has a rectangular contour. The lid 30 may be fixed to the container 22 using fasteners and / or a press fit engagement with a second end 42 of the side wall. In some embodiments, a gasket (not shown) may be disposed between the second end 42 of the side wall and the lid 30.

[0029] The container 22 includes a plate-shaped base 23 and side walls 40 protruding from the base 23. Further, the container 22 includes an ECU output connector 80 and an ECU input connector 180. The side walls 40 protrude from the base 23 in a direction perpendicular to the inner surface 25 of the base 23 (e.g., facing the lid) and extend surrounding the periphery of the base 23. The side walls 40 are a four-sided structure including a first end 41 of the side wall joined to the base 23 and a second end 42 of the side wall defining the open end 28 of the container, which is opposite to the first end 41 of the side wall. The four surfaces of the side walls 40 include a first side wall portion 45, a second side wall portion 46 parallel to the first side wall portion 45 and spaced apart from the first side wall portion 45, a third side wall portion 47 extending between the first side wall portion 45 and the second side wall portion 46 on one side of the base 23, and a fourth side wall portion 48 parallel to the third side wall portion 47 and spaced apart from the third side wall portion 47. The fourth side wall portion 48 is disposed on the side of the base 23 opposite to the third side wall portion 47, and the third side wall portion 47 and the fourth side wall portion 48 are perpendicular to the first side wall portion 45 and the second side wall portion 46.

[0030] The ECU housing 21 has a height dimension corresponding to the distance along the Z axis between the outer surface 26 of the base 23 and the outer surface 31 of the lid 30, and a length dimension corresponding to the distance along the Y axis between the outer surface of the first side wall portion 45 and the outer surface of the second side wall portion 46. Further, the ECU housing 21 has a width dimension corresponding to the distance along the X axis between the third side wall portion 47 and the fourth side wall portion 48. The X axis, Y axis, and Z axis (Figure 3) are mutually perpendicular and provide a reference frame for the ECU housing 21.

[0031] The container 22 includes a generally rectangular first inner holding portion 49 surrounded by the side wall 40 and adjacent to the inner surface of the first side wall portion 45 and the inner surface of the base 23, and a generally rectangular second inner holding portion 50 surrounded by the side wall 40 and adjacent to the inner surface of the second side wall portion 46 and the inner surface of the base 23. The first holding portion 49 and the second holding portion 50 provide structural reinforcement for the container 22 and accommodate and support portions of the pins 86, 186, as will be described in detail below. The surfaces of the first holding portion 49 and the second holding portion 50 facing the lid are recessed with respect to the second end 42 of the side wall, and portions of the PCB 120 are placed on the surfaces of the first holding portion 49 and the second holding portion 50 facing the lid, whereby the PCB 120 is supported parallel to the base 23 and in a spaced relationship with respect to the base 23 and the lid 30.

[0032] The container 22 includes positioning posts 34 that project from the base 23 and are used to position the PCB 120 with respect to the side wall 40. Each post 34 includes a proximal end integrally formed with the base 23 and a distal end opposite the proximal end. Each positioning post 34 has a sufficient length (e.g., the distance between the proximal end and the distal end) such that the distal end is located within the container 22 adjacent to the open end 28 of the container.

[0033] The container 22 includes an ECU output connector 80, which is integrally formed with the first side wall portion 45. The ECU output connector 80 includes a first shroud 81, the first side wall portion 45, the first inner holding portion 49, and an array of output connector pins 86 extending through the first shroud 81.

[0034] The first shroud 81 includes a first tubular portion 82 and an outer support block 84. The first tubular portion 82 has the shape of a rectangular tube and protrudes outward from the outer surface of the first side wall portion 45 in a direction perpendicular to the first side wall portion 45. The first tubular portion 82 surrounds the outer support block 84 that protrudes from the outer surface of the first side wall portion 45. In some embodiments, the first tubular portion 82 is configured to enable an interlocking engagement with another electrical connector, such as the motor unit electrical connector 6 for example. The outer support block 84 is recessed with respect to the open end 83 of the first tubular portion 82 and is at least partially aligned with the first inner holding portion 49 in a direction parallel to the Y axis. Together with the first side wall portion 45 and the first inner holding portion 49, the outer support block 84 supports the output connector pin 86.

[0035] A portion of each output connector pin 86 is embedded in the container 22. More specifically, a portion of each output connector pin 86 is embedded in the first outer support block 84, the first side wall portion 45, and the first inner holding portion 49. As will be described in detail below, the embedded portion of the output connector pin 86 is irregularly shaped and engages with the container 22 such that each output connector pin 86 has zero degrees of freedom of movement with respect to the container 22 and is firmly supported by the container 22 regardless of the direction of the force applied to the pin 86.

[0036] In the illustrated embodiment, the ECU output connector 80 includes four output connector pins 86, and these output connector pins 86 are arranged in a 2×2 array 85. The two pins 86(1) in the upper row of the array (for example, the column closest to the lid 30) are each a conductive alpha-type output connector pin, and the two pins 86(2) in the lower row of the array (for example, the column closest to the base 23) are each a conductive beta-type output connector pin. Each alpha output connector pin 86(1) is aligned with a beta output connector pin 86(2) in the height direction of the ECU housing 21 (for example, the direction perpendicular to the base 23), and is aligned with another alpha output connector pin 86(1) in the width direction of the ECU housing 21 (for example, the direction perpendicular to the third side wall portion 47). Each beta output connector pin 86(2) is aligned with another beta output connector pin 86(2) in the width direction of the ECU housing 21. In the following description, references to the overall pin structure include general reference numbers without branch numbers. For example, the output connector pin "86" refers to both alpha output connector pins and beta output connector pins. Further, the reference numeral with "(1)" attached refers to the structure of the alpha output connector pin 86(1), and the reference numeral with "(2)" attached refers to the structure of the beta output connector pin 86(2).

[0037] Referring to FIGS. 7 to 16, the details of the configurations of the alpha output connector pin 86 and the beta output connector pin 86, and the details of the engagement between the alpha output connector pin 86 and the beta output connector pin 86 and the container 22 will be described in detail below.

[0038] Each of the alpha output connector pin 86 and the beta output connector pin 86 includes a first end 87, a second end 88, and an intermediate portion disposed between the first end 87 and the second end 88. Further, each of the alpha output connector pin 86 and the beta output connector pin 86 extends along a longitudinal axis 89 that extends between the first end 87 and the second end 88. The first end 87 of each output connector pin 86 includes a female first electrical connection portion 90, and the second end 88 of each output connector pin 86 includes a male second electrical connection portion 91. As viewed in a side view (FIG. 15), the alpha output connector pin 86 and the beta output connector pin 86 have a generally L-shaped outer profile including a longitudinal portion 68 and a transverse portion 69. The longitudinal portion 68 extends in a direction parallel to the longitudinal axis 89, and the first electrical connection portion 90 projects from one end of the longitudinal portion 68. The transverse portion 69 extends in a direction perpendicular to the longitudinal axis 89 and away from the lid-facing surface of the base 23. The second electrical connection portion 91 projects from one end of the transverse portion toward the lid 30. With this configuration, the first electrical connection portion 90 extends in a direction perpendicular to the direction of the second electrical connection portion 91.

[0039] In some embodiments, each of the alpha output connector pin 86 and the beta output connector pin 86 may be formed from a thin strip of conductive material that is punched, bent, and / or folded from a blank to achieve the illustrated configuration. As a result, the pin 86 is blade-shaped and has a small material thickness relative to its overall length and height.

[0040] In the illustrated embodiment, the alpha output connector pin 86(1) includes a bent portion 93 disposed between the first end 87 and the midpoint 92 of the pin 86(1). The bent portion 93 has a U-shaped cross-section when the pin 86(1) is viewed in a direction parallel to the longitudinal axis 89(1). The legs 93(a), 93(b) of the folded portion 93 are open facing one side of the beta output connector pin 86(2). While one leg 93(a) coincides with the longitudinal axis 89(1), the opposite leg 93(b) is spaced from the longitudinal axis 89(1) in the width direction of the pin 86(1). The legs 93(a), 93(b) of the folded portion 93 have protrusions 93(c), which protrude longitudinally and are bent so as to converge with each other to provide a female-type first electrical connection portion 90. In use, the male pin of a mating electrical connector (not shown) is received in the space between the protrusions 93(c), and the end portions of the protrusions 93(c) engage the outer surface of the male pin to form an electrical connection with the outer surface of the male pin.

[0041] The alpha output connector pin 86(1) includes a flat portion 94 disposed between the intermediate point 92 and the second end 88 of the pin. The flat portion 94 is aligned with the longitudinal axis 89(1). The height of the flat portion 94 is non-uniform such that the height of the pin 86(1) at the intermediate point 92 is greater than the height of the pin 86(1) near the second end 88 of the pin. A shoulder 99 is formed at the height transition. The shoulder 99 faces the second end 88 of the pin. A rectangular spring element 95 is provided on the flat portion 94 at a location between the intermediate point 92 and the shoulder 99. In the illustrated embodiment, the spring element 95 is a rectangular tab. The spring element 95 is integral with the flat portion 94 along one edge and projects from the flat portion 94 such that the edge of the tab on the side opposite the one edge is spaced from the flat portion 94. As a result, the spring element 95 is at an acute angle to the flat portion 94. A first flange 96 is provided on the flat portion 94 at a location between the shoulder 99 and the second end 88. The first flange 96 projects in a direction perpendicular to the longitudinal axis 89 from the edge of the pin 86(1) and has a central opening 97. In the illustrated embodiment, the first flange 96 projects in a direction opposite to the direction of the spring element 95. An elbow 98 of the pin 86(1) that provides an L-shape to the pin 86(1) is disposed between the first flange 96 and the second end 88 of the pin. The elbow 98 causes the male second electrical connection portion 91 to extend in a direction perpendicular to the longitudinal axis 89.

[0042] The alpha output connector pin 86(1) has a length dimension (e.g., the distance between the first end 87 and the second end 88 of the pin 86(1)) that is significantly larger than the width dimension and the height dimension of the pin 86(1). For example, the alpha output connector pin 86(1) may have a length that is at least three times the width dimension and the height dimension. Further, the alpha output connector pin 86(1) has a height dimension (e.g., the dimension in the direction parallel to the insertion direction of the second electrical connection portion 91) that is larger than the width dimension (e.g., the dimension in the direction perpendicular to the longitudinal axis of the second electrical connection portion 91 and the insertion direction). For example, the alpha output connector pin 86(1) may have a height that is approximately twice the width dimension. The thickness of the material used to form the alpha output connector pin 86(1) is extremely small with respect to the length, height, or width of the pin 86(1). For example, in the illustrated embodiment, the length of the alpha output connector pin 86(1) is at least 50 times the thickness of the material used to form the alpha output connector pin 86(1).

[0043] The beta output connector pin 86(2) may be formed from a thin strip of conductive material, and this thin strip is punched, bent, and flexed from a blank to achieve the illustrated configuration. In the illustrated embodiment, the beta output connector pin 86(2) is generally flat and omits the folded portion of the alpha output connector pin 86(1). The beta output connector pin 86(2) is longer than the alpha output connector pin 86(1). The beta output connector pin 86(2) has a height dimension that is larger than the height of the alpha output connector pin 86(1) and a width dimension that is smaller than the width of the alpha output connector pin 86(1). The thickness of the material used to form the beta output connector pin 86(2) may be the same as the thickness of the material used to form the alpha output connector pin 86(1).

[0044] Each of the beta output connector pins 86(2) includes an elongated slot 100 that opens at a first end 87 of the pin and defines a part of a first electrical connection portion 90 of the beta output connector pin 86(2). In the illustrated embodiment, the slot 100 extends in a direction parallel to the longitudinal axis 89, and the longitudinal dimension of the slot 100 ranges from 10% to 30% of the length of the beta output connector pin 86(2). The slot 100 has a neck portion 101 adjacent to the first end 87 of the pin. The slot 100 has a generally uniform height dimension in the region between the neck portion 101 and the blind end 114 of the slot 100. The remaining part of the first electrical connection portion 90 of the beta output connector pin 86(2) is formed by the pin material surrounding the slot 100. This material defines opposing parallel arms 102(a), 102(b). Each of the parallel arms 102(a), 102(b) has an inwardly projecting portion 103 corresponding to the neck portion 101 of the slot 100. In use, a male pin of a mating electrical connector (not shown) is received in the slot 100, and the inwardly projecting portion 103 acts as a tooth. This tooth engages the outer surface of the male pin and forms an electrical connection with the outer surface of the male pin.

[0045] Each of the beta output connector pins 86(2) includes a flat portion 104 disposed between the first electrical connection portion 90 and the second end 88. The flat portion 104 includes the midpoint 105 of the beta output connector pin 86(2). The height of the flat portion 104 is non-uniform such that the height of the pin 86(2) at the midpoint 105 is greater than the height of the pin 86(2) near the second end 88 of the pin. A pair of shoulders 106, 107 are formed at the height transition, and each shoulder 106, 107 faces the second end 88 of the pin. A second flange 108 is provided on the flat portion 94 at a location between the midpoint 105 and the second end 88. The second flange 108 projects in a direction perpendicular to the longitudinal axis 89 from the edge of the pin 86(2) and has a central opening 109.

[0046] The elbow 112 of the pin 86(2), which provides an L-shape to the pin 86(2), is disposed between the second flange 108 and the second end 88 of the pin. By the elbow 112, the male second electrical connection portion 91 extends in a direction perpendicular to the longitudinal axis 89. At the location between the elbow 112 and the second electrical connection portion 91, a rectangular notch 110 is provided in the flat portion 94.

[0047] In each of the beta output connector pins 86(2), the first electrical connection portion 90, the flat portion 104, the elbow 112, the rectangular notch, and the second electrical connection portion 91 are located in a plane including the longitudinal axis 89(2). In use, this plane is perpendicular to the container base 23.

[0048] The beta output connector pin 86(2) has a length dimension (e.g., the distance between the first end 87 and the second end 88 of the pin 86(2)) that is significantly larger than its width and height dimensions. For example, the beta output connector pin 86(2) may have a length that is at least five times the dimensions of the width and height. Further, the beta output connector pin 86(2) has a height dimension (e.g., the dimension in the direction parallel to the insertion direction of the second electrical connection portion 91) that is larger than the width dimension (e.g., the dimension perpendicular to the longitudinal axis and the insertion direction of the second electrical connection portion 91). For example, the beta output connector pin 86(2) may have a height that is approximately twice the width dimension.

[0049] In array 85, the alpha output connector pin 86 and the beta output connector pin 86 are oriented such that the first flange of the alpha output connector pin 86(1) overlaps the second flange 108 of the beta output connector pin 86(2), and the respective central openings 97, 109 are aligned in the Z-axis direction. In array 85, the first end 87 of the alpha output connector pin 86(1) overlaps the first end 87 of the beta output connector pin 86(2) and is longitudinally aligned with the first end 87 of the beta output connector pin 86(2). Further, the longitudinal axis 89 of the alpha output connector pin 86(1) is offset in the X direction with respect to the longitudinal axis 89 of the beta output connector pin 86(2). Further, the second electrical connection portion 91 of the alpha output connector pin 86(1) is aligned with the second electrical connection portion 91 of the beta output connector pin 86(2) in the height direction or Z direction.

[0050] Each of the alpha output connector pin 86 and the beta output connector pin 86 is partially embedded in the container 22 such that its longitudinal axis 89 is parallel to the Y (e.g., length) direction of the ECU housing 21, the flat portions 94, 104 are parallel to the Y-Z plane, and the first flange 96 and the second flange 108 are parallel to the X-Y plane. Each of the alpha output connector pin 86 and the beta output connector pin 86 is partially embedded in the container 22 such that the first electrical connection portion 90 is exposed and disposed outside the ECU housing 21. The first electrical connection portion 90 is surrounded by the tubular portion 82 of the shroud. Further, each of the alpha output connector pin 86 and the beta output connector pin 86 is partially embedded in the container such that the second electrical connection portion 91 is exposed and disposed inside the ECU housing 21. With this configuration, the second electrical connection portion 91 can form an electrical connection portion with the PCB 120.

[0051] Referring to FIGS. 7-9 and FIGS. 17-20, the alpha output connector pins 86 and the beta output connector pins 86 are assembled to the container 22 of the ECU housing 21 in an overmolding process. With respect to the alpha output connector pin 86(1), during the overmolding process, the material used to form the container 22 fills the portion of the folding portion 93 (e.g., the folding portion excluding the protrusion 93(c)) and the flat portion 94 including the shoulder 99, the first flange 96, and the elbow 98. Further, the material flows around the spring element 95 and into the central opening 97 of the first flange, and the material cooperates with these elements to facilitate holding the pin 86(1) in a desired position relative to the container 22. With respect to the beta output connector pin 86(2), during the overmolding process, the material used to form the ECU housing 21 fills the flat portion 104 including the shoulders 106, 107, the second flange 108, and the elbow 112. Further, the material flows into the central opening 109 and the notch 110 of the second flange, and the material cooperates with these elements to facilitate holding the pin 86(2) in a desired position relative to the container 22 of the ECU housing 21.

[0052] As described above, the portions of the alpha output connector pin 86(1) and the beta output connector pin 86(2) embedded in the container 22 have an irregular shape. The irregular shape of the alpha output connector pin 86(1) and the beta output connector pin 86(2) engages with the container 22 such that the alpha output connector pin 86(1) and the beta output connector pin 86(2) have zero degrees of freedom of movement relative to the container 22. In particular, the container 22 and the pins 86(1), 86(2) are engaged so as to cooperate with each other such that the axial movement of each of the pins 86(1), 86(2) in the X, Y, and Z directions is blocked, and the rotational movement of each of the pins 86(1), 86(2) about the X-axis, Y-axis, and Z-axis is blocked.

[0053] To achieve the above-described cooperating engagement, each pin 86(1), 86(2) includes at least a pair of flat surfaces that are perpendicular to the X-axis line and are located on opposite sides of each other and abut against the corresponding surface of the container 22. Each alpha output connector pin 86(1) and each beta output connector pin 86(2) include at least a pair of first pin surfaces 61 and second pin surfaces 62 that are located on opposite sides of each other and correspond to the main surfaces located on opposite sides of, for example, the flat portions 94, 104. The first pin surface 61 faces and abuts against the first container portion 51, and the second pin surface 62 faces and abuts against the second container portion 52 (FIG. 18). The first pin surface 61 and the second pin surface 62, and the respective abutting surfaces of the first container portion 51 and the second container portion 52 define surfaces that are parallel to the Y-Z plane. In another example, the legs 93(a), 93(b) of the folding portion 93 define a wide surface that is parallel to the flat portion 94 and parallel to the Y-Z plane (FIG. 19). The legs 93(a), 93(b) of the folding portion 93 face and abut against the surface of the outer support block 84.

[0054] Each pin 86 includes at least a pair of opposing planes that are perpendicular to the Y-axis line and abut against the corresponding surface of the container 22. For example, each alpha output connector pin 86(1) and each beta output connector pin 86(2) include opposing third pin surfaces 63 and fourth pin surfaces 64. For example, the third pin surface 63 corresponds to the shoulders 99, 106, 107, and the fourth pin surface 64 corresponds to the facing surfaces of the lateral portion 69 of the pin (FIGS. 8, 9). In each of the alpha output connector pin 86 and the beta output connector pin 86, the third pin surface 63 faces and abuts against the third container portion 53, and the fourth pin surface 64 faces and abuts against the fourth container portion 54. The third pin surface 63 and the fourth pin surface 64, and the respective abutting surfaces of the third container portion 53 and the fourth container portion 54 define surfaces that are parallel to the X-Z plane.

[0055] In another example, the short side surfaces 94a, 94b, 104a, 104b located on opposite sides of the flat portions 94, 104 are parallel to the wide surfaces of the first flange 96 and the second flange 108, and define a plane parallel to the X-Y plane (FIG. 8). The short side surfaces 94a, 94b, 104a, 104b located on opposite sides of the flat portions 94, 104 are in contact with the surfaces of the outer support block 84.

[0056] Each pin 86 includes at least a pair of flat surfaces located on opposite sides and perpendicular to the Z-axis line, which are in contact with the corresponding surfaces of the container 22. For example, each alpha output connector pin 86(1) and each beta output connector pin 86(2) include a fifth pin surface 65 and a sixth pin surface 66 located on opposite sides, which correspond to the wide surfaces located on opposite sides of the first flange 96 and the second flange 108. The fifth pin surface 65 is in contact with the fifth container portion 55, and the sixth pin surface 66 is in contact with the sixth container portion 56 (FIG. 17). The fifth pin surface 65 and the sixth pin surface 66, and the respective contact surfaces of the fifth container portion 55 and the sixth container portion 56 define a plane parallel to the X-Y plane.

[0057] In another example, the short side surfaces 94a, 94b, 104a, 104b located on opposite sides of the flat portions 94, 104 are parallel to the wide surfaces of the first flange 96 and the second flange 108, and define a plane parallel to the X-Y plane (FIG. 8). The short side surfaces 94a, 94b, 104a, 104b located on opposite sides of the flat portions 94, 104 are in contact with the surfaces of the outer support block 84.

[0058] Each pin 86 includes flat surfaces 61, 62 located on at least one pair of opposite sides perpendicular to the X-axis line, flat surfaces 63, 64 located on at least one pair of opposite sides perpendicular to the Y-axis line, and flat surfaces 65, 66 located on at least one pair of opposite sides perpendicular to the Z-axis line. Each of the flat surfaces 61, 62, 63, 64, 65, 66 abuts against the corresponding surfaces 51, 52, 53, 54, 55, 56 of the container 22, so the translational movement of the pin 28 in any of the X-direction, Y-direction, and Z-direction is blocked. Further, the rotation of the pin 86 about any of the X-axis line, Y-axis line, and Z-axis line is blocked.

[0059] In use, the male second electrical connection portion 91 of each pin 86 is received in and electrically connected to a corresponding one of the electrical connection plugs 125 of the PCB.

[0060] In the illustrated embodiment, the ECU output connector 80 is a multi-pin latch connector, but another embodiment may have a different configuration. In the illustrated embodiment, the ECU output connector 80 is an overmolded female connector, and this female connector is functionally compatible with an electrical input portion provided in an electrical driving device such as the electrical connector 6 of the motor unit.

[0061] Referring to FIGS. 3 to 7 and FIG. 21, the container 22 includes an ECU input connector 180 integrally formed with the second side wall portion 46. The ECU input connector 180 includes a second shroud 181, a second side wall portion 46, a second inner holding portion 50, and an array of input connector pins 186 extending through the second shroud 181, the second side wall portion 46, and the second inner holding portion 50.

[0062] The second shroud 181 includes a second tubular portion 182. The second tubular portion 182 has the shape of a rectangular tube and protrudes outward from the outer surface of the second side wall portion 46 in a direction perpendicular to the second side wall portion 46. The second tubular portion 182 surrounds an array of input connector pins 186 that protrude from the outer surface of the second side wall portion 46. The second side wall portion 46 and the second inner holding portion 50 support the array of input connector pins 186. In some embodiments, the second tubular portion 182 is configured to enable an interlocking engagement with another electrical connector.

[0063] A portion of each input connector pin 186 is embedded in the container 22. More specifically, a portion of each input connector pin 186 is embedded in the outer support block 84, the first side wall portion 45, and the first inner holding portion 49. The embedded portions of the input connector pins 186 are irregularly shaped and engaged with the container 22 such that each input connector pin 186 has zero degrees of freedom of movement with respect to the container 22 and is firmly supported by the container 22 regardless of the direction of the force applied to the pin 186.

[0064] In the illustrated embodiment, the ECU input connector 180 includes five input connector pins 186, which are arranged in a 1×5 array 185. The two outermost pins 186(1) of the array 185 are each a conductive gamma-type input connector pin, and the three middle pins 186(2) of the array 185 are each a conductive delta-type input connector pin. Each gamma input connector pin 186(1) is aligned with a delta-type input connector pin 186(2) in the width direction of the ECU housing 21 (e.g., a direction perpendicular to the third side wall portion 47).

[0065] Each of the gamma input connector pin 186(1) and the delta input connector pin 186(2) includes a first end portion 187, a second end portion 188, and an intermediate portion disposed between the first end portion 187 and the second end portion 188. Further, each of the gamma input connector pin 186(1) and the delta input connector pin 186(2) extends along a longitudinal axis 189 extending between the first end portion 187 and the second end portion 188. The first end portion 187 of each input connector pin 186 includes a male first electrical connection portion 190, and the second end portion 188 of each input connector pin 186 includes a male second electrical connection portion 191. As seen in a side view (FIG. 7), the gamma input connector pin 186(1) and the delta input connector pin 186(2) have a generally L-shaped outer profile including a longitudinal portion 168 and a transverse portion 169. The longitudinal portion 168 extends in a direction parallel to the longitudinal axis 189, and the first electrical connection portion 190 projects from one end of the longitudinal portion 168. The transverse portion 169 extends in a direction perpendicular to the longitudinal axis 189 and away from the lid-facing surface of the base 23. The second electrical connection portion 191 projects from one end of the transverse portion toward the lid 30. With this configuration, the first electrical connection portion 190 extends in a direction perpendicular to the second electrical connection portion 191.

[0066] In some embodiments, each of the gamma input connector pins 186 and the delta input connector pins 186(1), 186(2) may be formed from a strip of thin conductive material that has been punched, bent and / or folded from a blank to achieve the illustrated configuration. As a result, the pins 186(1), 186(2) are blade-shaped and have a small material thickness relative to their overall length and height. In the illustrated embodiment, the gamma input connector pin 186(1) has a pin width that is at least twice the width of the delta input connector pin 186(2). Further, each second electrical connection portion 191 of each delta input connector pin 186(2) is a single male connector, while each second electrical connection portion 191 of each gamma input connector pin 186(1) is a double male connector.

[0067] In the illustrated embodiment, the ECU input connector 180 may be configured to receive power and data from the LIN. In the illustrated embodiment, the ECU input connector 180 is an overmolded male connector.

[0068] As described above, the container 22 is configured to engage each output connector pin such that axial movement of each output connector pin 86 in the X, Y, and Z directions is prevented, and rotational movement about the X, Y, and Z axes of each pin is prevented. In other words, the portion of each output connector pin 86 that is embedded in the container 22 has an irregular shape and engages the container 22 such that the pin 86 has zero degrees of freedom of movement relative to the container 22. This is achieved by manufacturing a housing assembly that positions the output connector pins 86 in place using an overmolding manufacturing process. A method of manufacturing the container 22 will then be described.

[0069] Referring to FIG. 22, a method of manufacturing a housing assembly (e.g., container 22) includes the following method steps. In a first step (step 200), conductive output connector pins 86(1), 86(2) and input connector pins 186(1), 186(2) are provided. In particular, the output connector pins 86(1), 86(2) and input connector pins 186(1), 186(2) are arranged in an array as suitable for the application and then placed in a cavity (not shown) of an injection mold. Following the first step, the output connector pins 86(1), 86(2) and input connector pins 186(1), 186(2) are overmolded with the container 22 (e.g., insert molding) using injection of material into the mold such that each of the pins 86(1), 86(2), 186(1), 186(2) is partially embedded in a part of the container 22 (step 202). In particular, the first electrical connection portions 90, 190 are arranged outside the container 22, the second electrical connection portions 91, 191 are arranged inside the container 22, and each of the pins 86(1), 86(2), 186(1), 186(2) is partially embedded such that the portions of the pins 86(1), 86(2), 186(1), 186(2) embedded in the container material engage the container 22 such that the pins 86(1), 86(2), 186(1), 186(2) have zero degrees of freedom of movement relative to the container. The lid 30 of the ECU housing 21 is molded separately from the container 22 and is attached to the open end 28 of the container following attachment of the PCB 120.

[0070] Referring to FIGS. 23 to 29, the container 222 of the alternative embodiment is similar to the container 22 described above, and common reference numerals are used to indicate common elements. The container 222 of the alternative embodiment is different from the container 22 described above in that the container 222 includes an ECU output connector 280 of the alternative embodiment integrally formed with the first side wall portion 45. The ECU output connector 280 is different from the output connector 80 described above in that the ECU output connector 280 includes alternative alpha connector pins 286(1) in the array 285. This array 285 also includes the beta connector pins 82(2) described above with respect to FIGS. 12 and 13. In particular, the ECU output connector 280 includes four output connector pins 86 arranged in a 2×2 array 285. Two alpha connector pins 286(1) are arranged in the upper row of the array, and two beta connector pins 86(2) are arranged in the lower row of the array. Each alpha output connector pin 286(1) is aligned with the beta output connector pin 86(2) in the height direction of the ECU housing 21 (for example, a direction perpendicular to the base 23), and is aligned with another alpha output connector pin 286(1) in the width direction of the ECU housing 21 (for example, a direction perpendicular to the third side wall portion 47). Each beta output connector pin 86(2) is aligned with another beta output connector pin 86(2) in the width direction of the ECU housing 21. Next, the configuration of the alpha output connector pin 286(1) and the details of the engagement between the alpha output connector pins 286(1), 86(2) and the container 222 will be described in detail.

[0071] Each of the alpha output connector pins 286(1) includes a first end 87, a second end 88, and an intermediate portion disposed between the first end 87 and the second end 88. Further, each of the alpha output connector pins 286(1) extends along a longitudinal axis 89 that extends between the first end 87 and the second end 88. The first end 87 of each alpha output connector pin 286(1) includes a female first electrical connection portion 90, and the second end 88 of each alpha output connector pin 286(1) includes a male second electrical connection portion 91. As viewed in a side view (FIG. 24), the alpha output connector pin 286(1) has a generally L-shaped outer profile that includes a longitudinal portion 68 and a transverse portion 69. The longitudinal portion 68 extends in a direction parallel to the longitudinal axis 89, and the first electrical connection portion 90 projects from one end of the longitudinal portion 68. The transverse portion 69 extends in a direction perpendicular to the longitudinal axis 89 and away from the lid-facing surface of the base 23. The second electrical connection portion 91 projects from one end of the transverse portion toward the lid 30. With this configuration, the first electrical connection portion 90 extends in a direction perpendicular to the second electrical connection portion 91.

[0072] In some embodiments, each of the alpha output connector pins 286(1) may be formed from a strip of thin conductive material that has been punched, bent, and / or folded from a blank to achieve the illustrated configuration. As a result, the alpha output connector pin 286(1) is blade-shaped and has a small material thickness relative to its overall length and height.

[0073] Each of the alpha output connector pins 286(1) includes an elongated slot 200 which opens at the first end 87 of the pin and defines a part of the first electrical connection portion 90 of the alpha output connector pin 286(1). In the illustrated embodiment, the slot 200 extends in a direction parallel to the longitudinal axis 89, and the longitudinal dimension of the slot 200 is in the range of 10% to 30% of the length of the alpha output connector pin 286(1). The slot 200 has a neck portion 201 adjacent to the first end 87 of the pin. The slot 200 tapers so as to have a minimum dimension at the blind end 214 in the region between the neck portion 201 and the blind end 214 of the slot 200. The remaining part of the first electrical connection portion 90 of the alpha output connector pin 286(1) is formed by the pin material surrounding the slot 200. This material defines opposing parallel arms 202(a), 202(b). Each of the parallel arms 202(a), 202(b) has an inwardly projecting portion 203 corresponding to the neck portion 201 of the slot 200. Further, each of the parallel arms 202(a), 202(b) includes a shallow curved notch 210 formed along the edge of each arm 202(a), 202(b) facing away from the slot 200. When viewed in plan view (Figure 25), the curved notch 210 has a maximum depth at a location aligned with the slot blind end 214. In use, a male pin of a mating electrical connector (not shown) is received in the slot 200 and the inwardly projecting portions 203 act as teeth. These teeth engage the outer surface of the male pin and form an electrical connection with the outer surface of the male pin.

[0074] Each of the alpha output connector pins 286(1) includes a flat portion 204 disposed between a first electrical connection portion 90 and a second end 88. The flat portion 204 includes an intermediate point 205 of the alpha output connector pin 286(1). The height dimension of the flat portion 204 matches the thickness of the plate used to form the pin, while the width dimension of the flat portion 204 is about 20 percent of the length dimension of the pin 286(1). The width dimension of the flat portion 204 is non-uniform since a rectangular notch 211 is provided at one of its peripheries. A shoulder 206 is formed at the width transition, and the shoulder 206 faces the second end 88. A first flange 296 is provided on the flat portion 204 at a location between the intermediate point 208 and the second end 88. The first flange 296 projects in a direction perpendicular to the longitudinal axis 89 from the blind edge 207 of the rectangular notch 211 and includes a central opening 209. The first flange 296 is in the same plane as the flat portion 204.

[0075] An elbow 212 of the alpha output connector pin 286(1) that provides an L-shape to the pin 286(1) is disposed between the first flange 296 and the second end 88 of the pin. Due to the elbow 212, a male second electrical connection portion 91 extends in a direction perpendicular to the longitudinal axis 89.

[0076] In each of the alpha output connector pins 286(1), the first electrical connection portion 90 and the flat portion 204 are located in a first plane including the longitudinal axis 89(1), and the elbow 212 and the second electrical connection portion 91 are located in a second plane perpendicular to the longitudinal axis 89(1). In use, the first plane is parallel to the base 23 of the container, and the second plane is perpendicular to the base 23 of the container.

[0077] The alpha output connector pin 286(1) has a length dimension (e.g., the distance between the first end 87 and the second end 88 of the pin 86(1)) that is significantly larger than its width and height dimensions. For example, the alpha output connector pin 286(1) may have a length that is at least three times its width and height dimensions. Further, the alpha output connector pin 286(1) has a width dimension that is larger than its height dimension. The thickness of the material used to form the alpha output connector pin 286(1) is extremely small relative to the length, height, or width of the pin 286(1). For example, in the illustrated embodiment, the length of the alpha output connector pin 286(1) is at least 50 times the thickness of the material used to form the alpha output connector pin 286(1).

[0078] In the array 285, the alpha output connector pin 286(1) and the beta output connector pin 86(2) are oriented such that the first flange 296 of the alpha output connector pin 286(1) overlaps the second flange 108 of the beta output connector pin 86(2), and their respective central openings 209, 109 are aligned in the Z-axis direction. In the array 285, the first end 87 of the alpha output connector pin 286(1) overlaps the first end 87 of the beta output connector pin 86(2) and is longitudinally aligned with the first end 87 of the beta output connector pin 86(2). Further, the longitudinal axis 89 of the alpha output connector pin 86(1) is aligned in the X direction with respect to the longitudinal axis 89 of the beta output connector pin 86(2). Further, the second electrical connection portion 91 of the alpha output connector pin 286(1) is aligned in the height or Z direction with the second electrical connection portion 91 of the beta output connector pin 86(2).

[0079] Each of the alpha output connector pin 86 and the beta output connector pin 86 is partially embedded in the container 22 such that its respective longitudinal axis 89 is parallel to the Y (e.g., length) direction of the ECU housing 21. The flat portion 204 of the alpha output connector pin 286(1) is parallel to the X-Y plane, while the flat portion 104 of the beta output connector pin 86(2) is parallel to the Y-Z plane, and the first flange 96 and the second flange 108 are parallel to the X-Y plane. The second electrical connection portion 91 of the alpha output connection pin 286(1) is present in the X-Z plane, while the second electrical connection portion 91 of the beta output connection pin 86(2) is present in the Y-Z plane. Each of the alpha output connector pin 286(1) and the beta output connector pin 86(2) is partially embedded in the container 22 such that the first electrical connection portion 90 is exposed and disposed outside the ECU housing 21. The first electrical connection portion 90 is surrounded by the tubular portion 82 of the shroud. Further, each of the alpha output connector pin 286(1) and the beta output connector pin 86(2) is partially embedded in the container such that the second electrical connection portion 91 is exposed and disposed inside the ECU housing 21. With this configuration, the second electrical connection portion 91 can form an electrical connection portion with the PCB 120.

[0080] Similar to the above-described embodiment, the alpha output connector pin 286 and the beta output connector pins 86(1), 86(2) are assembled in the container 222 of the ECU housing 21 in an overmolding process. Regarding the alpha output connector pin 286(1), during the overmolding process, the material used to form the container 222 embeds the flat portion 204 including the notch 205, the shoulder 206, and the first flange 296. Further, the material also embeds a part of the curved notch 210. In particular, this material can embed the alpha output connector pin 286(1) between the first flange 296 and the blind end 214 of the slot 200.

[0081] As described above, the portions of the alpha output connector pins 286(1) and beta output connector pins 86(2) embedded in the container 22 have irregular shapes. The irregular shapes of the alpha output connector pins 286(1) and beta output connector pins 86(2) engage with the container 22 such that the alpha output connector pins 286(1) and beta output connector pins 86(2) have zero degrees of freedom of movement with respect to the container 222. In particular, the container 222 and the pins 286(1), 86(2) are engaged to cooperate with each other such that axial movement of each of the pins 286(1), 86(2) in the X, Y, and Z directions is blocked, and rotational movement of each of the pins 286(1), 86(2) about the X, Y, and Z axes is blocked.

[0082] The illustrated alternative embodiments of the housing assembly for the ECU have been described in some detail above. It should be understood that only the structures considered necessary to clarify the housing assembly are described in this specification. Other conventional structures, as well as the structures of the accessory and auxiliary components of the housing assembly and the ECU, are assumed to be known and understood by those skilled in the art. Further, although embodiments of the housing assembly have been described above, the housing assembly is not limited to the above embodiments and can be implemented with various different design changes without departing from the housing assembly described in the claims.

Claims

1. A housing assembly, the housing assembly comprising: A housing, the housing including a container and a lid, The container comprising: A base, A side wall protruding from the base in a direction perpendicular to the base, a first end of the side wall being connected to the base and a second end of the side wall defining a container opening, the side wall; And The lid being shaped and dimensioned to close the container opening, The housing; And a conductive pin extending through a first portion of the side wall. And The conductive pin includes an alpha output connector pin disposed in the upper row of the array and a beta output connector pin disposed in the lower row of the array, The alpha output connector pin includes a first end including a first electrical connection portion and a folding portion disposed between the first end and a midpoint of the alpha output connector pin, The beta output connector pin includes an elongated slot that opens at a first end where there is no folding portion and that defines a part of the first electrical connection portion of the beta output connector pin, A second end of each pin includes a second electrical connection portion, Each pin is partially embedded in the container such that the first electrical connection portion is exposed and disposed outside the housing and the second electrical connection portion is exposed and disposed inside the housing, and The portion of the pin embedded in the container is irregularly shaped and engages the container such that each pin has zero degrees of freedom of movement with respect to the container. A housing assembly.

2. The housing assembly according to claim 1, wherein the first electrical connection portion has a female electrical connection configuration.

3. The container further comprising: An inner retaining portion adjacent to the first portion of the side wall and protruding inwardly from the inner surface of the side wall; And an outer support block adjacent to the first portion of the side wall and protruding outwardly from the outer surface of the side wall. And Each pin extends through the first portion of the side wall, the inner retaining portion, and the outer support block. The housing assembly according to claim 1.

4. The housing assembly according to claim 3, wherein the outer support block is surrounded by a tubular shroud.

5. The container includes a shroud that protrudes outward from the first portion of the side wall, the shroud defining an outer opening that surrounds the first end of the pin and is configured to engage a corresponding mating connector. The housing assembly according to claim 3.

6. The housing has a height dimension that matches the distance along the Z-axis between the outer surface of the base and the outer surface of the lid, a length dimension that matches the distance along the Y-axis between the outer surface of the first portion of the side wall and the outer surface of the second portion of the side wall that is parallel to and spaced from the first portion of the side wall, and a width dimension that matches the distance along the X-axis between the third portion of the side wall and the fourth portion of the side wall that are perpendicular to the first and second portions of the side wall and spaced apart from each other, and the X-axis, the Y-axis, and the Z-axis are perpendicular to each other, the container is configured to prevent axial movement of each pin with respect to the X-axis, the Y-axis, and the Z-axis and to prevent rotational movement of each pin about the X-axis, the Y-axis, and the Z-axis. The housing assembly according to claim 1.

7. Each pin has a first pair of opposing flat surfaces that are perpendicular to the X-axis, a second pair of opposing flat surfaces that are perpendicular to the Y-axis, and a third pair of opposing flat surfaces that oppose the Z-axis, and each of the first, second, and third pairs of opposing flat surfaces abuts against the container, and the container is configured to prevent axial movement of each pin in the X, Y, and Z directions and to prevent rotational movement of each pin about the X-axis, the Y-axis, and the Z-axis. The housing assembly according to claim 6.

8. The housing assembly according to claim 1, comprising a printed circuit board disposed within the housing, the printed circuit board including electrical connection plugs, and the second electrical connection portions of each pin being electrically connected to a corresponding one of the electrical connection plugs.

9. The portion of each pin embedded in the container has an L-shaped outer profile. The housing assembly according to claim 1.

10. The housing assembly according to claim 1, wherein each pin has a through opening, and a material used to form the container fills the through opening.

11. The housing assembly according to claim 1, wherein each pin has a flange protruding from the surface of each pin.

12. The housing assembly according to claim 1, wherein at least some of the pins have an integral spring element protruding from the side surface of each pin.

13. The housing assembly according to claim 1, wherein the pins are fixed in position with respect to the container by an overmolding manufacturing process.

14. A housing assembly, the housing assembly comprising A housing, the housing including a container and a lid, The container comprises A base, A side wall protruding from the base in a direction perpendicular to the base, a first end of the side wall being connected to the base, and a second end of the side wall defining a container opening, the side wall Including The lid is shaped and dimensioned to close the container opening The housing, A pin extending through a first portion of the side wall, Each pin A first end including a female first electrical connection portion, A second end including a second electrical connection portion, A longitudinal portion extending in a first direction perpendicular to the first portion of the side wall, the longitudinal portion including the first electrical connection portion, the first electrical connection portion being oriented to form an electrical connection in a direction parallel to the first direction, the longitudinal portion A transverse portion extending in a second direction perpendicular to the longitudinal axis and the surface of the base facing the lid, the transverse portion including the second electrical connection portion, the second electrical connection portion being oriented to form an electrical connection in a direction parallel to the second direction, the transverse portion Including The pins include alpha output connector pins arranged in the upper row of the array and beta output connector pins arranged in the lower row of the array. The alpha output connector pin includes a first end including a first electrical connection portion and a folding portion disposed between the first end and the midpoint of the alpha output connector pin. The beta output connector pin includes an elongated slot that is open at a first end that defines a part of the first electrical connection portion of the beta output connector pin and has no folding portion, Each pin has the first electrical portion exposed and disposed outside the housing, has the second electrical portion exposed and disposed inside the housing, and the embedded portion of the pin engages the container such that the pin has zero degrees of freedom of movement with respect to the container, is partially embedded in the container, housing assembly.

15. A method of manufacturing a housing assembly including a housing and pins protruding from the housing, the method comprising: providing conductive pins, each pin having a first end with a female first electrical connection portion, a second end opposite the first end and having a second electrical connection portion, and an intermediate portion disposed between the first end and the second end, the intermediate portion having an elbow shape such that the first end extends along a first axis and the second end extends along a second axis perpendicular to the first axis, including, wherein the conductive pins include alpha output connector pins disposed in an upper row of an array and beta output connector pins disposed in a lower row of the array, the alpha output connector pins including a first end including a first electrical connection portion and a folding portion disposed between the first end and an intermediate point of the alpha output connector pin, the beta output connector pin including an elongated slot that is open at a first end that defines a part of the first electrical connection portion of the beta output connector pin and has no folding portion, step; forming a housing around the pins, wherein the first electrical connection portion is disposed outside the housing, the second electrical connection portion is disposed inside the housing, and the embedded portion of the pin engages the housing such that the pin has zero degrees of freedom of movement with respect to the housing, each pin being partially embedded in a portion of the housing, step and having.

16. The method of claim 15, wherein the step of forming the housing includes an overmolding process in which the pins are partially embedded. **Claim 17** The step of forming the housing includes a container having a base, a side wall protruding from the base in a direction perpendicular to the base, a first end of the side wall being connected to the base, and a second end of the side wall defining a container opening, the side wall The method of claim 15, including forming a container having. **Claim 18** The step of providing the conductive pins includes arranging the pins within an array in which each pin is spaced from an adjacent pin of the array and parallel to the adjacent pins of the array, The method of claim 15, wherein the step of providing the conductive pins is performed before the step of forming the housing.

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