Electrical connector and method of assembling said electrical connector with a printed circuit board and at least one electrical component

Abstract

The present invention relates to an electrical connector (2) electrically connecting a printed circuit board (1) with an electrical component (3), the printed circuit board (1) having a first face (5) and a second face (7) opposed to the first face (5), the first face (5) and the second face (7) being joined together through a side wall (9), the electrical connector (2) comprising a base (4) in contact with the electrical component (3) and at least two retaining elements (6), each retaining element (6) being configured to be in mechanical contact with the second face (7) of the printed circuit board (1), the printed circuit board (1) having a cut-out portion receiving the electrical connector (2) so that elastic deformations of the retaining elements (6), perpendicularly to and towards the second face (7), allows to maintain the mechanical contact between each retaining element (6) and the second face (7) of the printed circuit board (1), the mechanical contact between each retaining element (6) and the second face (7) of the printed circuit board (1) being accessible through the opening.

Description

DESCRIPTIONELECTRICAL CONNECTOR AND METHOD OF ASSEMBLING SAID ELECTRICAL CONNECTOR WITH A PRINTED CIRCUIT BOARD AND AT LEAST ONE ELECTRICAL COMPONENTTECHNICAL FIELD OF THE INVENTION

[0001] The present invention generally relates to the field of an electric or a hybrid vehicle.

[0002] More specifically, the invention relates to an electrical assembly provided with an electrical connector for such a vehicle.BACKGROUND ART

[0003] As is known, an electric or a hybrid automotive vehicle comprises an electric drive comprising an electric motor (i.e. a rotary electric machine) which needs to be supplied with electric power, for instance by a high voltage power supply battery, to deliver a mechanical power in order to ensure the propulsion of the vehicle. The electric motor comprises a stator, referring to a fixed part of the electric motor, and a rotor, referring to a rotating part of the electric motor. The electric drive further comprises an inverter configured to convert a direct current voltage coming from a high-voltage power supply battery into an alternating current voltage so as supply the stator of the electric motor with the AC voltage.

[0004] The electric drive and other elements of the vehicle generates vibrations, which are transmitted to the electronical components of the vehicle. Conventionally, electrical components linked to a Printed Circuit Board (PCB) of an inverter rely on mechanical fasteners, such as screws or rivets, to secure said component to the PCB. While these methods offer a degree of stability, they can introduce stress points, causing vibration-related issues to the PCB or others components mounted on the PCB. This kind of fasteners also presents tolerancing problems, complicating assembly operations.

[0005] The invention remedies the disadvantages of the state of the art by proposing a solution for connecting an electrical component to a PCB, allowing tolerances to be adjusted, simplifying the manufacturing process of an electrical equipment such as an inverter, and allowing to dampen vibrations transmitted to the PCB.SUMMARY OF THE INVENTION

[0006] According to a first aspect of the invention, there is provided an electrical connector configured for electrically connecting a substantially planar printed circuit board with an electrical component, the printed circuit board having a first face configured to receive a printed circuit and a second face opposed to the first face, the first face and the second face being joined together through a side wall, the electrical connector comprising a base configured to be in contact withthe electrical component and at least two retaining elements, each retaining element being configured to be in direct mechanical contact with the second face of the printed circuit board, the printed circuit board having a cut-out portion receiving the electrical connector so that elastic deformations of the retaining elements, perpendicularly to and towards the second face, allow to maintain the direct mechanical contact between each retaining element and the second face of the printed circuit board and delimits an opening, the direct mechanical contact between each retaining element and the second face of the printed circuit board being accessible through the opening.

[0007] This combination of features enables to connect an electrical component mechanically and electrically to an electronic board such as a printed circuit board. By deforming elastically, such an electrical connector attenuates the vibrations transmitted by the electronic component to the printed circuit board, increasing the safety of said board and of other electronic components mounted on such a board. Furthermore, the elastic deformation eliminates tolerance errors during assembly, ensuring that the connector is pressed tightly against the printed circuit board. Also, such an opening allows an operator to easily weld the electrical connector and the printed circuit board, the area of contact between the electrical connector and the second face of the printed circuit board 1 being directly accessible through the opening.

[0008] According to a further aspect, each retaining element comprises a Z-shape structure, the Z-shape structure having a first end integral with the base and a second end configured to be in direct mechanical contact with the second face of the printed circuit board, the Z-shape structure having elastically deformable portions. As a result, a “spring” effect is achieved through the Z- shape structure, enhancing the pressing of the electrical connector against the second face of the printed circuit board. The elastically deformable portions of the Z-shape structure are located at the vertices of the “Z”. When the Z-shape structure undergoes through a compressive force, the elastically deformable portions are subjected to a bending according to beam theory.

[0009] Advantageously, each retaining element is configured to be in direct mechanical contact with the side wall of the printed circuit board. Therefore, the holding of the electrical connector in contact with the printed circuit board is improved, the contact surface being enhanced.

[0010] Advantageously, the electrical connector comprises a first retaining element configured to be in direct mechanical contact with both the second face of the printed circuit board and a first portion of the side wall, the electrical connector further comprising a second retaining element configured to be in direct mechanical contact with both the second face of the printed circuit board and a second portion of the side wall, the elastic deformation of the first retaining element and the second retaining element being perpendicular to and towards the second face, the first portion of the side wall and the second portion of the side wall facing each other. As a result, a “spring”effect is achieved through the Z-shape structure of each retaining element facing each other, enhancing the pressing of the electrical connector against the side wall of the printed circuit board when a transversal effort is applied to the electrical connector.

[0011] Advantageously, the electrical connector comprises a third retaining element configured to be in direct mechanical contact with both the second face of the printed circuit board and the first portion of the side wall, the electrical connector further comprising a fourth retaining element configured to be in direct mechanical contact with both the second face of the printed circuit board and the second portion of the side wall, the third retaining element being elastically deformable in the same way as the first retaining element and the fourth retaining element being elastically deformable in the same way as the second retaining element. Therefore, with four retaining elements, the number of degrees of freedom of the electrical connector relative to the printed circuit board is reduced by eliminating any possibility of rotation of the electrical connector.

[0012] Advantageously, the first retaining element and the third retaining element are attached to each other through a first spacer and the second retaining element and the fourth retaining element are attached to each other through a second spacer. As a result, the stiffness of the retaining elements is improved.

[0013] Advantageously, the first spacer is in direct mechanical contact with the first portion of the side wall and the second spacer is in direct mechanical contact with the second portion of the side wall. Therefore, the spacers allow more contact surface between the side walls and the retaining elements.

[0014] Advantageously, the base of the electrical connector is substantially planar, said base extending parallel to the printed circuit board. As a result, the base has more contact surface with the end of the electrical component, improving the robustness of the assembly.

[0015] Advantageously, the base comprises a contact portion in direct mechanical contact with the electrical equipment and a recessing portion, the recessing portion being opposite to an area of the direct mechanical contact with the electrical component. The recessing portion can act as a dust collector, collecting dust from abrasion and welding of the printed circuit board with the electrical connector.

[0016] According to another aspect of the invention, there is provided an electrical assembly comprising:- an electrical connector of any of claims as described hereinbefore;- a substantially planar printed circuit board;- at least one electrical component; the electrical connector electrically connecting the printed circuit board and the electrical component.

[0017] According to another aspect of the invention, there is provided a method of assembling an electrical assembly as described hereinbefore, the method comprising:- welding the base of the electrical connector to the electrical component;- cutting out the cut-out portion receiving the electrical connector on the printed circuit board;- inserting the electrical connector in the cut-out portion of the printed circuit board by elastically deforming the retaining elements by applying a compressive force in a direction opposite to the second face of the printed circuit board;- releasing the retaining elements so that an elastic deformation of the retaining elements of the electrical connector, allowing to maintain a direct mechanical contact between each retaining element and the second face of the printed circuit board;- welding each retaining element to the second face of the printed circuit board.BRIEF DESCRIPTION OF DRAWINGS

[0018] Other features and advantages of the present invention will emerge from the following description of embodiments of the invention provided as non-limitative examples for achieving various aspects of the invention. The description refers to the attached figures which illustrate, also by way of example, an embodiment of the inventions:Figure 1 shows an isometric view of an electrical connector and an electrical component in accordance with a first embodiment of the present invention;Figure 2 shows an isometric view of an electrical connector in accordance with another embodiment of the present invention;Figure 3 shows an isometric view of the electrical connector of figure 2 in an electrical assembly according to a further aspect of the invention;Figure 4 shows an isometric view of an electrical connector in accordance with another embodiment of the present invention.DETAILED DESCRIPTION

[0019] With reference to figure 1 , there is provided an electrical connector 2. The electrical connector 2 comprises a base 4 configured to be in contact with an electrical component 3. Furthermore, the electrical connector 2 comprises at least two retaining elements 6. The retaining elements 6 are configured to be elastically deformable. Here, the retaining elements 6 are all identical.

[0020] In the described embodiment, the retaining elements 6 comprise each a Z-shape structure 8, each Z-shape structure 8 having a first end 10 integral with the base 4, a second end 12 and elastically deformable portions 14. The elastically deformable portions 14 are extending between the first end 10 and the second end 12 of each Z-shape structure. In particular, the deformable portions 14 are located at the vertices of the “Z”. When the Z-shape structure undergoes through a compressive force, the elastically deformable portions are subjected to a bending according to beam theory.

[0021] The base 4 of the electrical connector 2 is substantially planar, so that the mechanical contact between the electrical component 3 and the electrical connector 2 is maximised. Furthermore, the base 4 comprises a contact portion 20 configured to be in direct mechanical contact with the electrical component 3, and a recessing portion 22. The recessing portion 22 is opposite to an area of the direct mechanical contact 20 with the electrical component 3.With reference to figure 2 and figure 3, there is provided an electrical connector 2 according another embodiment of the invention. Particularly, on figure 3, the electrical connector 2 is illustrated inside of an electrical assembly according a further aspect of the invention. The electrical assembly comprises an electrical component 3 as described hereinbefore and a substantially planar printed circuit board 1 . The electrical connector 2 is configured to electrically and mechanically connect the printed circuit board 1 and the electrical component 3. The printed circuit board 1 comprises a first face 5 configured to receive a printed circuit and a second face 7 opposed to the first face 5. The first face 5 and the second face 7 are joined together through a side wall 9.

[0022] The retaining elements 6 are configured to be in direct mechanical contact with the second face 7 of the printed circuit board 1 . Here, the printed circuit board 1 has a cut-out portion configured to receive the electrical connector 2, so that the elastic deformations of the retaining elements 6, perpendicularly and to and towards the second face 7 of the printed circuit board 1 allow to maintain the direct mechanical contact between each retaining element 6 and the second face 7 of the printed circuit board. This combination of features enables to connect the electrical component 3 mechanically and electrically to the printed circuit board 1 . By deforming elastically, the electrical connector 2 attenuates the vibrations transmitted by the electronic component 3 to the printed circuit board 1 , increasing the safety of said printed circuit board 1 and of otherelectronic components mounted on such a board. Furthermore, the elastic deformation eliminates tolerance errors during assembly, ensuring that the electrical connector 2 is pressed tightly against the printed circuit board 1 . The cut-out portion is shown here as being located on edges of the printed circuit-board 1 , but can alternatively be realised inside of the printed circuit-board 1 , so that the side wall 9 delimits a closed outline.

[0023] Furthermore, the direct mechanical contact between each retaining element 6 and the second face 7 of the printed circuit board 1 is accessible through an opening. The opening allows an operator to easily weld the electrical connector 2 and the printed circuit board 1 together, the area of contact between the electrical connector 2 and the second face 7 of the printed circuit board 1 being directly accessible through the opening.

[0024] In the embodiment of the electrical connector 2 described on figure 1 , figure 2 and figure 3, the retaining elements 6 are configured to be in direct mechanical contact with both the second face 7 of the printed circuit board 1 and the side wall 9 of the printed circuit board 1 . Therefore, the holding of the electrical connector 2 in contact with the printed circuit board 1 is improved, the contact surface being enhanced.

[0025] The electrical connector 2 of figure 2 and figure 3 differs from the electrical connector 2 of figure 1 in that it comprises a first retaining element 6 in direct mechanical contact with both the second face 7 of the printed circuit board 1 and a first portion 11 of the side wall 9 and a second retaining element 6 in direct mechanical contact with both the second face 7 of the printed circuit board 1 and a second portion 13 of the side wall 9, the first portion 11 of the side wall 9 and the second portion 13 of the side wall 9 facing each other. Here, the Z-shape structure 8 of the first and second retaining elements 6 are also facing each other, the “Z” being oriented in opposite directions. In other words, the electrical connector 2 has a first symmetrical plane and a second symmetrical plane, the Z-shape structures 8 of the first and second retaining elements 6 being each on a side of the first plane and being crossed by the second plane. The first plane and the second plane are orthogonal. As a result, a “spring” effect is achieved through the Z-shape structures 8 of each retaining element 6 facing each other, enhancing the pressing of the electrical connector 2 against the side wall 9 of the printed circuit board 1 when a transversal effort is applied to the electrical connector 2.

[0026] Independently from the first and second retaining element 6, the electrical connector 2 can comprise a third retaining element 6 in direct mechanical contact with both the second face 7 of the printed circuit board 1 and the first portion 11 of the side wall 9, the electrical connector 2 further comprising a fourth retaining element 6 in direct mechanical contact with both the second face 7 of the printed circuit board 1 and the second portion 13 of the side wall 9, the third retaining element 6 being elastically deformable in the same way as the first retaining element 6 and thefourth retaining element 6 being elastically deformable in the same way as the second retaining element 6. As the first and second retaining element 6, the Z-shape structure 8 of the third and fourth retaining elements 6 are also facing each other, the “Z” being oriented in opposite directions. With four retaining elements 6 facing each other two by two, the number of degrees of freedom of the electrical connector 2 relative to the printed circuit board 1 is reduced, notably by eliminating any possibility of rotation of the electrical connector 2 inside of the cut-out portion of the printed circuit board 1 .

[0027] The electrical connector 2 of figure 2 and figure 3 also differs from the electrical connector 2 of figure 1 in that it comprises a first spacer 16 attaching the first retaining element 6 and the third retaining element 6 together. The first spacer 16 can be welded to the first and third retaining element 6, but can alternatively be made in one-piece with both the first and third retaining element 6. The electrical connector 2 of figure 2 and figure 3 further comprises a second spacer 18 attaching the second retaining element 6 and the fourth retaining element 6 together. The second spacer 18 can be welded to the second and fourth retaining element 6, but can alternatively be made in one-piece with both the second and fourth retaining element 6. The first and second spacer 16, 18 increase the stiffness of the retaining elements 6.

[0028] As shown on figure 3, the first spacer 16 and the second spacer 18 (hidden by the printed circuit board 1 ), are in direct mechanical contact with respectively the first portion 1 1 of the side wall 9 for the first spacer 16 and the second portion 13 of the side wall 9 for the second spacer 18. Therefore, the spacers 16,18 allow more contact surface between the portions 11 , 13 of the side wall 9 and the retaining elements 6.

[0029] To achieve the assembly of the electrical assembly shown in figure 3, there is provided a method of assembling according to a further aspect of the invention. The method comprises the steps:- welding the base 4 of the electrical connector 2 to the electrical component 3;- cutting out the cut-out portion receiving the electrical connector 2 on the printed circuit board 1 ;- inserting the electrical connector 2 in the cut-out portion of the printed circuit board 1 by elastically deforming the retaining elements 6 by applying a compressive force in a direction opposite to the second face 7 of the printed circuit board 1 ;- releasing the retaining elements 6 so that an elastic deformation of the retaining elements 6 of the electrical connector 2 allows to maintain a direct mechanical contact between each retaining element 6 and the second face 7 of the printed circuit board 1 ;- welding each retaining element 6 to the second face 7 of the printed circuit board 1 .

[0030] The present invention has been described with regard to preferred embodiments. The description as much as the drawings were intended to help the understanding of the invention, rather than to limit its scope. It will be apparent to one skilled in the art that various modifications may be made to the invention without departing from the scope of the invention herein, and such modifications are intended to be covered by the present description. The invention is defined by the claims that follow.

[0031] Particularly, the electrical connector 2 can comprise a first retaining element 6 and a second retaining element as shown on figure 4. The electrical connector of figure 4 differs from the embodiment shown on figure 2 and figure 3 in that the first spacer 16 is only attached to the first retaining element 6 and that the second spacer 18 is only attached to the second retaining element 6. Moreover, the electrical connector 2 comprises here a first symmetry plane, the Z- shape structure 8 of the first retaining element 6 and the first spacer being on one side of the first symmetry plane and the Z-shape structure 8 of the second element 6 and the second spacer being on the other side of the first symmetry plane. In this particular embodiment, the electrical connector 2 is achieved with less material, reducing its manufacturing cost while providing an adequate holding.

Claims

CLAIMS1. Electrical connector (2) configured for electrically connecting a substantially planar printed circuit board (1 ) with an electrical component (3), the printed circuit board (1 ) having a first face (5) configured to receive a printed circuit and a second face (7) opposed to the first face (5), the first face (5) and the second face (7) being joined together through a side wall (9), the electrical connector (2) comprising a base (4) configured to be in contact with the electrical component (3) and at least two retaining elements (6), each retaining element (6) being configured to be in direct mechanical contact with the second face (7) of the printed circuit board (1 ), the printed circuit board (1 ) having a cut-out portion receiving the electrical connector (2) so that elastic deformations of the retaining elements (6), perpendicularly to and towards the second face (7), allow to maintain the direct mechanical contact between each retaining element (6) and the second face (7) of the printed circuit board (1 ) and delimits an opening, the direct mechanical contact between each retaining element (6) and the second face (7) of the printed circuit board (1 ) being accessible through the opening.

2. Electrical connector (2) according to claim 1 , wherein each retaining element (6) comprises a Z-shape structure (8), the Z-shape structure (8) having a first end (10) integral with the base (4) and a second end (12) configured to be in direct mechanical contact with the second face (7) of the printed circuit board (1 ), the Z-shape structure (8) having elastically deformable portions (14).

3. Electrical connector (2) according to any claim 1 to 2, wherein each retaining element (6) is configured to be in direct mechanical contact with the side wall (9) of the printed circuit board (1 ).

4. Electrical connector (2) according to claim 2 to 3, wherein a first retaining element (6) is configured to be in direct mechanical contact with both the second face (7) of the printed circuit board (1 ) and a first portion (11 ) of the side wall (9), the electrical connector (2) further comprising a second retaining element (6) configured to be in direct mechanical contact with both the second face (7) of the printed circuit board (1 ) and a second portion (13) of the side wall (9), the elastic deformation of the first retaining element (6) and the second retaining element (6) being perpendicular to and towards the second face (7), the first portion (1 1 ) of the side wall (9) and the second portion (13) of the side wall (9) facing each other.

5. Electrical connector (2) according to claim 4, comprising a third retaining element (6) configured to be in direct mechanical contact with both the second face (7) of the printed circuit board (1 ) and the first portion (11 ) of the side wall (9), the electrical connector (2) further comprising a fourth retaining element (6) configured to be in direct mechanical contact with both the second face (7) of the printed circuit board (1 ) and the second portion (13) of the side wall (9), the third retaining element (6) being elastically deformable in the same way as the first retainingelement (6) and the fourth retaining element (6) being elastically deformable in the same way as the second retaining element (6).

6. Electrical connector (2) according to claim 5, wherein the first retaining element (6) and the third retaining element (6) are attached to each other through a first spacer (16) and the second retaining element (6) and the fourth retaining element (6) are attached to each other through a second spacer (18).

7. Electrical connector (2) according to claim 6, wherein the first spacer (16) is in direct mechanical contact with the first portion (11) of the side wall (9) and the second spacer (18) is in direct mechanical contact with the second portion (13) of the side wall (9).

8. Electrical connector (2) according to any of claims 1 to 8, wherein the base (4) of the electrical connector (2) is substantially planar, said base (4) extending parallel to the printed circuit board (1 ).

9. Electrical connector (2) according to claim 8, wherein the base (4) comprises a contact portion (20) in direct mechanical contact with the electrical component (3) and a recessing portion (22), the recessing portion (22) being opposite to an area of the direct mechanical contact (20) with the electrical component (3).

10. Electrical assembly comprising:- the electrical connector (2) of any of claims 1 to 9;- a substantially planar printed circuit board (1);- at least one electrical component (3); the electrical connector (2) electrically connecting the printed circuit board (1 ) and the electrical component (3).

11. A method of assembling the electrical assembly of claim 10, the method comprising the steps:- welding the base (4) of the electrical connector (2) to the electrical component (3);- cutting out the cut-out portion receiving the electrical connector (2) on the printed circuit board- inserting the electrical connector (2) in the cut-out portion of the printed circuit board (1 ) by elastically deforming the retaining elements (6) by applying a compressive force in a direction opposite to the second face (7) of the printed circuit board (1);- releasing the retaining elements (6) so that an elastic deformation of the retaining elements (6) of the electrical connector (2) allows to maintain a direct mechanical contact between each retaining element (6) and the second face (7) of the printed circuit board (1);- welding each retaining element (6) to the second face (7) of the printed circuit board (1).

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