Electrical connectors – With coupling movement-actuating means or retaining means in... – For direct connection to a flexible tape or printed circuit...
Reexamination Certificate
2000-04-20
2001-10-09
Sircus, Brian (Department: 2839)
Electrical connectors
With coupling movement-actuating means or retaining means in...
For direct connection to a flexible tape or printed circuit...
C439S507000
Reexamination Certificate
active
06299469
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to printed circuit boards and in particular to a method and apparatus for splicing segments of flexible circuit boards when servicing or replacing electronic components in automobiles.
Automobiles include many complex electrical assemblies for use in sophisticated engine control systems including a variety of sensors for detecting such conditions as engine temperature, throttle position, engine speed and air intake. These control systems typically include microprocessors to process the signals from these sensors and produce control signals for operating engine components such as throttle valves, ignition coils and fuel injectors.
Ordinarily, the electronics in such control systems are interconnected via a printed circuit board. Printed circuit boards are used because they provide reliable connection between the electronic components. Typical circuit boards have a rigid substrate on which the circuit is printed. Due to their rigid construction, the electronics on the circuit board must be connected to sensors and vehicle components by a wiring harness. Wiring harnesses are costly and are prone to failure in the connection of the harness to the circuit board but also in the connection to connector pins. Moreover, wiring harnesses clutter the engine compartment making it more difficult to assemble and service the engine.
One method of providing reliable connections without using bulky and expensive wiring harnesses is to use flexible circuit boards typically made of a conductive layer laminated to a flexible insulating substrate. Such flexible circuit boards can be fabricated to include finger-like extensions that are sufficiently flexible to follow a curved path between the control circuitry and the sensor or vehicle component.
Such flexible circuit boards provide the advantage of obviating wire harnesses. Moreover, using such circuit boards can also eliminate pin connectors between the circuit board and the sensors or vehicle components, which can decrease cost as well as connection related problems. However, like wires, the finger-like extensions can be damaged from flexure and abrasion occurring during normal use of the automobile. And, without connectors between the circuit board and the sensors or components, it is ordinarily more difficult and expensive to service or replace components of the electrical assembly. This is because the remote components are directly connected to a main circuit board by the integral extensions. Thus, replacing one sensor or vehicle component ordinarily requires that the entire assembly to which it is connected be replaced.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a connector for splicing uniquely configured flexible circuit boards when servicing electrical assemblies. In an automobile environment, the present invention permits the use of flexible circuit boards having integral finger-like extensions running directly to vehicle components without using connectors such that a single electronic component can be replaced without replacing the entire assembly.
Specifically, the present invention provides a clamp for splicing flexible circuit boards each having a flexible substrate supporting an electrically conductive circuit with at least one electrically conductive contact pad proximate alignment openings. The clamp has a first plate with a lateral channel sized to receive the circuit boards as well as alignment posts projecting from within the channel. The clamp also has a second plate hinged to the first plate. The second plate has alignment post recesses and one or more lateral metallic jumpers with conductive ends extending toward the first plate. In use, the circuit boards are aligned end to end in the first plate and the plates are clamped together. This causes the jumper to contact the contact pads of each circuit board and couple them electrically.
One aspect of the present invention is a kit for use with an automobile electronic assembly. The electronic assembly has a first electronic component mounted to a flexible circuit board with a finger-like extension. The extension is made of a flexible substrate supporting runs of conductors having electrically conductive contact pads. The kit includes a second electronic component having electrical terminals, a replacement extension and a splice connector. The replacement extension is made of a flexible substrate supporting runs of conductors having electrically conductive contact pads at one end. The replacement extension is electrically coupled to the electrical terminals of the second component at another end. The splice connector has conductive jumpers that bridge the contact pads of the extension to the contact pads of the replacement extension so that the first electronic component is electrically coupled to the second electronic component.
Another aspect of the invention is a method for servicing electronic assemblies in automobiles having a first electronic component with a flexible circuit board and a flexible extension supporting conductor runs that couple the first electronic component to a second electronic component. The flexible circuit extension is cut cross-wise so that the extension is in two segments. A first segment is connected to the first electronic component and a second segment is connected to the second electronic component. Then, the first electronic component and the first extension segment are removed and a replacement component is installed. The free ends of the second extension segment and a replacement extension segment are brought together so that the conductor runs of the second extension segment are aligned with conductor runs of the replacement extension segment. A splice connector is then clamped over the free ends so that metallic jumpers bridge the conductor runs of the extension segments.
Still another aspect of the invention includes a flexible circuit board having a conductor circuit supported by a flexible substrate. Finger-like extensions of the board support runs of conductors connected at one end to the conductor circuit of the board body. The extensions have a pre-defined splice region wherein the splice region is defined by laterally aligned conductive contact pads coupled to the conductor runs of increased width than the conductor runs.
Thus, the present invention provides a quick and easy method and apparatus for servicing electrical assemblies connected via a flexible circuit board. The present invention also obviates separate pin connectors between the components in the assembly, allowing the components to be directly connected to the flexible board. Despite this, only the failed or damaged components can be replaced without replacing the entire assembly. Thus, the present invention reduces initial material and assembly costs by obviating connectors and reduces replacement costs by facilitating replacement of only the failed or damaged component(s).
REFERENCES:
patent: 3038140 (1962-06-01), Haberland
patent: 3824529 (1974-07-01), Dorrell
patent: 5934930 (1999-08-01), Camps et al.
patent: 6132236 (2000-10-01), Kozel et al.
patent: 6193544 (2001-02-01), McGinnis
Glovatsky Andrew Zachary
Kalinowski Pawel
McMillan Richard Keith
Shelton Larry I.
Sircus Brian
Visteon Global Technologies Inc.
Webb Brian S.
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