Electrical connectors – With insulation other than conductor sheath – Metallic connector or contact secured to insulation
Reexamination Certificate
2000-05-02
2001-10-16
Paumen, Gary (Department: 2833)
Electrical connectors
With insulation other than conductor sheath
Metallic connector or contact secured to insulation
C439S620040
Reexamination Certificate
active
06302747
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a two position, on-off heating, ventilation and air conditioning (HVAC) electric actuator for the automotive industry, which includes a DC motor and gear train to produce correct speed-torque characteristics, and a modular connector to interface with a controller or power supply.
BACKGROUND OF THE INVENTION
Two-position (on-off) HVAC actuators are typically controlled by directly applying power to a drive motor. The actuators commonly use soldered leads, printed circuit boards, conductor stampings, or a combination to make connection between the motor terminals and the output connector.
The polarity of the applied power determines the direction of actuator rotation. The necessary electrical connection requires two conductive paths, connecting the two connector pins to two motor terminals. The actuator housing also typically forms the shroud for the connector around the connector pins.
The electrical connection is usually achieved via one of the following designs approaches:
1. Printed circuit board (PCB): a PCB is used to mount a pair of connector pins. Copper traces are screened onto the board, leading to two copper pads where motor terminals are attached (soldered). The motor is then electrically connected to these two terminals via lead wires, or directly.
2. Conductor stampings: two stampings are formed into the shape of a connector pin on one end, and motor terminal on the other end. These stampings are mechanically secured into the plastic actuator housing.
3. Flying leads: insulated lead wires are soldered onto the motor, and terminated with a connector. Lead wires are captured by the two halves of the actuator housing.
In
FIG. 1
, an example of a lower housing section
10
of an actuator housing is shown. A connector shroud
12
is integral with the housing section
10
and leads into the interior
14
of the housing actuator. A printed circuit board
16
is shown which fits into the lower housing section
10
such that two connector pins
18
a,
18
b
project into the connector shroud
12
.
A free end of the connector pins forms the electrical connection between a controller or a power supply inserted into the shroud
12
. The opposite ends of the connector pins are welded to the underside of the PCB
16
.
The connector pins are electrically connected to two trifurcated terminals
20
a,
20
b
by copper connectors screened to the underside of the PCB. The terminals
20
a,
20
b
are also welded at a free end on the underside of the PCB.
Optionally a capacitor can be secured to the underside of the PCB and be electrically connected between the terminals and the connector pins. The capacitor is commonly employed to reduce electromagnetic interference (EMI).
Interior
14
of the lower housing section
10
is exposed through the connector shroud
12
. This communication may allow entry of fluid to the actuator housing, and thereby potentially adversely affect the workings of the housing actuator.
The PCB and the other design approaches are expensive and exhibit weaknesses, ranging from allowing fluid ingress to the difficulty in adding additional components, such as a capacitor across the motor terminals.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a low-cost method of achieving electrical connection to the motor terminals of a DC motor in a two position HVAC actuator. The invention allows the flexibility of easily changing the connector configuration interfacing with a controller or power supply by making the connector a modular connector, providing effective fluid ingress prevention.
The modular connector design is fixed from the connector flange inward into a housing, and is flexible outward with respect to its pin configuration and shroud shape. This design allows different connector configurations to be utilized with minimal tooling investment. A capacitor can also be inserted and crimped to the connector pin stampings, prior to being over-molded, to provide additional EMI filtering.
The modular connector of the present invention is made up of two conductor stampings. Each conductor stamping includes a trifurcated terminal and a connector pin/blade. Two conductor stampings interconnected by a bridge are insert molded into a specified connector shroud configuration. After molding, the bridge is severed from the conductor stampings externally of the over molded connector.
The modular connector is positioned in a housing for a HVAC actuator so that the DC motor terminals are pressed into the two trifurcated terminals of the conductor stampings, now molded into the connector, making positive and ground connections. The connector placement/position leaves the connection shroud portion exposed in the final actuator assembly for easy connection with customer wiring. This concept also allows alternate customer connector wiring configurations to be made without actuator housing modifications. A molded-in capacitor can be added for EMI protection, if required by the customer.
The configuration of the upper and lower housing portions of the actuator housing includes a groove into which a flange of the connector shroud is placed. The cooperation of the flange of the connector shroud and the groove in the housing sections prevents ingress of fluid into the housing. The over molded modular connector only has the connector shroud projecting from the housing.
The female portion of the connector shroud receives a male connector interface with a controller or power supply for the actuator. The shroud houses two connector pins for making the connection with the controller or power supply. The configuration of the connector shroud is easily changed to accommodate individual customer shapes for a controller or power supply. The configuration of an elongated rail portion of the modular connector containing the two trifurcated terminals is maintained with constant dimensions even when changing the shroud configuration so as to cooperate with the terminal blades of a DC motor located within the actuator housing.
Accordingly, it is another object of the present invention to form a modular connector for an actuator of an HVAC actuator by over molding two metal stampings, each including a connector pin and a trifurcated terminal so as to form a connector shroud having a flange which cooperates with a groove in upper and lower housing sections of an actuator housing.
It is still another object of the present invention to provide a modular connector for placement in a groove defined between upper and lower housing sections of an actuator housing with the configuration of a connector shroud being changeable to accommodate different controllers or power supply configurations which cooperate with the connector shroud to control a motor contained in the actuator housing.
It is still yet another object of the present invention to form a modular connector having a connector shroud with a flange which cooperates with a groove in the upper and lower housing sections of an actuator housing so as to prevent ingress of fluid into the actuator housing.
It is still yet another object of the present invention to provide a modular connector cooperating internally of an actuator housing with a DC motor and having a connector shroud projecting from the actuator housing and including a flange for cooperating with the housing to prevent fluid ingress, with the connector shroud cooperating with a controller or power supply connection for the DC motor.
It is still another object of the present invention to provide a modular connector formed by over molding two stampings each having a connector pin and a trifurcated terminal with the two stampings interconnected by a bridge which is severed from the stampings after the over molding process.
These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings.
REFERENCES:
patent: 4225209 (1980-09-01), Hu
Bui Tanh M.
Rawls David W.
Buehler Products, Inc.
Gushi Ross
Jacobson & Holman PLLC
Paumen Gary
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