JP7746155B2 - Connectors, printed circuit boards, and electric motor modules - Google Patents

Description

The present invention relates to a connector, a printed circuit board on which the connector is mounted, and an electric motor module equipped with the printed circuit board.

In vehicles, electric motor modules that drive power windows, sliding doors, sunroofs, power seats, and other features are often provided as an ECU (Electronic Control Unit), which houses the electric motor that serves as the drive source and a printed circuit board that mounts electronic components for controlling it. In such cases, technology related to connectors on the printed circuit board that electrically connect the printed circuit board to the terminals of the electric motor has long been known.

For example, Patent Document 1 discloses a connector for mounting on a circuit board. This connector includes a base for mounting on the circuit board, a carrier region extending obliquely upward from the base, and a U-shaped receptacle connected to the carrier region at one free end and opening upward for a flat terminal of an electric motor. In particular, this carrier region allows for tolerance of positional errors when assembling the printed circuit board and electric motor.

Patent Document 2 also discloses a connector for mounting on a circuit board. This connector includes an insert body that connects to the terminals of an electric motor, a support part that stands alongside the insert body, a U-shaped bent part in the center of the support part and the insert body, a long pin that extends downward from the bottom of the support part, and a short pin that extends downward from the bottom of the insert body. The long pin is inserted into a hole in the printed circuit board and soldered, while the short pin is inserted. This allows for positional errors when assembling the printed circuit board and electric motor.

Patent Document 3 also discloses an electric motor module that includes an electric motor, a circuit board, and a housing that houses these. This electric motor module includes components including a first contact that connects to the terminals of the electric motor, a second contact that connects to the circuit board, and a central portion that connects these contacts. By fixing this central portion to the electric motor, it is possible to prevent the force applied when assembling the electric motor from affecting the second contact.

German Patent Specification No. 10121430C1 People's Republic of China Patent Publication No. 105870682A International Publication No. 2014016093A2

As mentioned above, when assembling the electric motor and printed circuit board of an in-vehicle ECU, electrical connections using metal terminals are required. However, because the printed circuit board is positioned and fixed to the motor housing using an outer case, variations between components can accumulate in the terminal area and cause misalignment, which can deform the terminals or damage electrical connections such as solder.

The present invention provides a connector that allows for misalignment of the connector on a printed circuit board relative to the terminals of an electric motor, reducing the risk of terminal deformation and damage to electrical connections, a printed circuit board on which this connector is mounted, and an electric motor module equipped with this printed circuit board. The present invention also reduces the area occupied by the connector on the printed circuit board of an ECU, which requires a high degree of integration.

In order to solve the above problems, a connector is provided which is provided on a printed circuit board having a circuit and is formed from a conductive plate which electrically connects the circuit to a mating terminal, the connector comprising: a board mounting portion having a plurality of protrusions at one end which are inserted into holes provided in the printed circuit board; an erect portion which extends from a part of the other end of the board mounting portion away from the printed circuit board, bends midway, and extends towards the printed circuit board; a facing portion which extends from the end of the erect portion substantially parallel to the printed circuit board so as to face the board mounting portion; and a terminal portion which is connected to the end of the facing portion at its lower part and receives, clamps, and electrically connects a mating terminal from a direction perpendicular to the board surface of the printed circuit board.
According to this, the board mounting portion receives, via the opposing portion and the upright portion, the force that may arise from misalignment in position or angle when the electric motor terminal is press-fitted into the terminal portion, making it easier for the position of the terminal portion to match the position of the electric motor terminal, and also dispersing stress to reduce the force applied to a specific point, thereby providing a connector that tolerates misalignment in position or angle of the connector on the printed circuit board relative to the electric motor terminal and reduces the risk of terminal deformation or damage to the electrical joint. Furthermore, by providing a three-dimensional upright portion as well as a surface-direction of the printed circuit board as a mechanism that can absorb stress, it is possible to reduce the area occupied by the connector on the printed circuit board of an ECU, which requires a high degree of integration.

Furthermore, the lower surface of the terminal portion may be in contact with the surface of the printed circuit board.
With this, since the underside of the terminal portion abuts against the surface of the printed circuit board, displacement of the electric motor terminal in the direction of press-fitting into the terminal portion is minimized, further reducing the risk of deformation of the terminal or damage to the electrical connection.

Furthermore, the connecting portion between the facing portion and the standing portion may have a first notch at a corner on the side where the facing portion extends from the end of the standing portion.
According to this, by providing a notch at the corner of the connection part with the standing part in the opposing part, the path for absorbing stress is lengthened, misalignment is tolerated, and the risk of deformation of the terminal or damage to the electrical joint can be further reduced.

Furthermore, the multiple protrusions provided at one end may be composed of a first protrusion provided on one side at a position farthest from the connection portion with the standing portion at the other end, a second protrusion provided on one side at a position closer than the first protrusion from the connection portion with the standing portion at the other end, and at least one third protrusion provided on the other side from the connection portion with the standing portion at the other end, and may be characterized by having a second notch portion at one corner of the connection portion between the board mounting portion and the standing portion.
According to this, by providing a notch portion at the corner of the board mounting portion on the first protrusion side of the connection portion with the standing portion, the path for absorbing stress is lengthened, further reducing the risk of damage to the electrical connection portion of the first protrusion.

In order to solve the above problem, there is provided a printed circuit board that mounts the above connector, the printed circuit board having a first hole at a position corresponding to the first protrusion and the second protrusion, and a second hole at a position corresponding to the third protrusion, the first protrusion being inserted into the first hole and soldered thereto and connected to the circuit, the second protrusion being inserted into the first hole and soldered thereto but not connected to the circuit, and the third protrusion being inserted into the second hole and fitted thereto but not soldered thereto.
This provides a printed circuit board that is configured to be less susceptible to stress on the first protrusion that is electrically connected to the circuit of the printed circuit board, thereby allowing for misalignment of the position and angle of the connector on the printed circuit board relative to the terminal of the electric motor, reducing the risk of deformation of the terminal or damage to the electrical joint.

In order to solve the above problem, an electric motor module is provided that includes an electric motor, the above-mentioned printed circuit board that receives electric power from the outside and supplies the power to the electric motor, a gear that outputs the power of the electric motor, and a storage section that stores the electric motor, the printed circuit board, and the gear, and the terminal section is electrically connected to the terminal of the electric motor.
This provides an electric motor module that, by including the above-mentioned printed circuit board, allows for misalignment of the position and angle of the connector on the printed circuit board relative to the terminals of the electric motor, reducing the risk of deformation of the terminals and damage to the electrical joints.

As explained above, the present invention provides a connector that allows for misalignment of the connector on the printed circuit board relative to the terminals of the electric motor, reducing the risk of terminal deformation and damage to the electrical joints, a printed circuit board on which this connector is mounted, and an electric motor module equipped with this printed circuit board. Furthermore, the present invention reduces the area occupied by the connector on the printed circuit board of an ECU, which requires a high degree of integration.

1A is a perspective view of an electric motor module according to a first embodiment of the present invention, and FIG. 1B is a perspective view of the same with a cover partially removed. 1A and 1B are perspective views of the electric motor module according to a first embodiment of the present invention, including a connection portion between an electrode of the electric motor in the electric motor module and a connector on a printed circuit board, respectively, as seen from the electric motor side and as seen from the external cable connector side; 1A and 1B are perspective views showing a printed circuit board in an electric motor module of a first embodiment of the present invention, a connector mounted on the printed circuit board, and electrodes of an electric motor connected to the connector, in which (A) is a perspective view seen from the external cable connector side, (B) is a perspective view seen from the electric motor side, and (C) is a perspective view seen from the back side of the printed circuit board. (A) Front view, (B) Top view, (C) Bottom view, (D) Left side view, (E) Right side view, (F) Oblique view from the upper left of the back, and (G) Oblique view from the upper right of the front of the connector of the electric motor module of the first embodiment of the present invention. 1A and 1B are perspective views showing a connector mounted on a printed circuit board in an electric motor module of a first embodiment of the present invention, in which (A) is a perspective view seen from the electric motor side, (B) is a perspective view seen from the external cable connector side, and (C) is a perspective view seen from the back side of the printed circuit board. 1 is a schematic diagram showing deformation of a connector mounted on a printed circuit board in an electric motor module of a first embodiment according to the present invention caused by electrodes of an electric motor that has undergone positional or rotational misalignment. FIG.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
<First Example>
1 to 6 , an electric motor module 100, a connector 200 used in the electric motor module 100, and a printed circuit board 20 on which the connector 200 is mounted will be described. The electric motor module 100 is mounted on a vehicle and used to drive power windows, sliding doors, sunroofs, power seats, etc. The electric motor module 100 is modularized by integrating the electric motor 10 that drives these components, a gear 30 having a final output shaft 31, the printed circuit board 20, etc. inside the electric motor module 100. When the electric motor module 100 is used to drive a power window, for example, it is mounted inside the door and raises and lowers the window glass via a window regulator.

The electric motor module 100 comprises an electric motor 10 as a drive source, a gear 30 that converts the axial direction of the final output shaft 31 to a direction perpendicular to the axial direction of the rotary shaft 11 of the electric motor 10, a printed circuit board 20 that mounts an external cable connector 23 for receiving power from the outside and electronic components 24 for driving the electric motor 10 from that power, and a storage section 40 and connector storage section 50 that store these components. The gear 30 is stored inside the storage section 40 and is not shown in the drawings in this specification.

The electric motor 10 is a DC motor having a rotating shaft 11 and may be either brushed or brushless, with no particular limitation. A worm (not shown) is attached to the rotating shaft 11, driving a gear 30. The electric motor 10 has two plate-shaped electrodes 12 for receiving power from an external cable via a printed circuit board 20. The gear 30 has a worm wheel (not shown) that meshes with the worm and a final output shaft 31 directly connected to the center of the worm wheel, and is rotatably housed in a housing 40. The worm wheel reduces the rotation speed of the rotating shaft 11 and transmits high torque to the final output shaft 31, which drives a regulator.

The storage section 40 stores the electric motor 10 and gear 30 as a single unit. The connector storage section 50 stores the printed circuit board 20 with the tip of the external cable connector 23 mounted on the printed circuit board 20 exposed to the outside so that it can be connected to an external cable (Figure 1).

The printed circuit board 20 is equipped with an external cable connector 23 for receiving power from the outside, electronic components 24 for driving the electric motor 10 from that power, and two connectors 200 connected to the electrodes 12 for supplying drive power to the electric motor 10 (Figure 2), and is wired with a circuit (not shown) that electrically connects these. The external cable connector 23 is configured to receive power from an external cable and be connectable to an external cable for sending and receiving signals from the outside. The electronic components 24 are electrical components such as capacitors and semiconductors. The printed circuit board 20 has through holes 21 and non-through holes 22 for arranging the connectors 200 (Figure 3). Details will be described later.

The connector 200 is formed by punching and bending a conductive plate that electrically connects the circuit on the printed circuit board 20 with the electrode 12 of the electric motor 10, which serves as the mating terminal. The connector 200 is generally composed of four parts: a board mounting portion 210, an upright portion 220, a facing portion 230, and a terminal portion 240 (Figure 4).

When the connector 200 is attached to the printed circuit board 20, the board mounting portion 210 is attached with its flat surface approximately perpendicular to the printed circuit board 20. The board mounting portion 210 has four protrusions, namely a first protrusion 211, a second protrusion 212, and two third protrusions 213, on one end 21E1 of its flat surface closest to the printed circuit board 20, which are inserted into holes provided in the printed circuit board 20 and attached to the printed circuit board 20.

The standing portion 220 extends from a portion near the center of the other end 21E2 of the flat surface of the board mounting portion 210 farthest from the printed circuit board 20, in a direction approximately perpendicular to the printed circuit board 20, i.e., away from the printed circuit board 20, with the same width. Furthermore, the standing portion 220 bends 180 degrees midway from the portion extending perpendicularly from the other end 21E2 of the board mounting portion 210, and extends approximately perpendicularly toward the printed circuit board 20, continuing with the same width to an end 22E1 that is approximately at the same position as the other end 21E2 of the board mounting portion 210 in a side view. The width of the standing portion 220 is smaller than the length of the board mounting portion 210 and the opposing portion 230 in a plane parallel to the board surface of the printed circuit board 20.

The facing portion 230 extends from the end 22E1 of the standing portion 220 to both sides, facing the board mounting portion 210, without being substantially parallel to the printed circuit board 20 and without contacting it. The flat surface of the facing portion 230, like the flat surface of the board mounting portion 210, is substantially perpendicular to the printed circuit board 20. In this embodiment, the facing portion 230 extends to both sides from the end 22E1 of the standing portion 220, but it may also extend to only one side toward the terminal portion 240. In a plane parallel to the board surface of the printed circuit board 20, the facing portion 230 has a length that is slightly shorter than but substantially the same as the board mounting portion 210, and extends to the end 23E1, which is substantially in the same position as the first protrusion 211 in a top or side view, on one side toward the terminal portion 240.

The terminal portion 240 is composed of a clamping portion 241 formed in a tuning fork shape to sandwich the plate-shaped electrode 12 of the electric motor 10, and a base portion 242 formed below the clamping portion 241. The base portion 242 is connected to the end portion 23E1 of the facing portion 230 at the lower base portion 242. The base portion 242 extends from the end portion 23E1 of the facing portion 230 in a direction perpendicular to the facing portion 230 and parallel to the printed circuit board 20. The flat surface of the base portion 242 is approximately perpendicular to the printed circuit board 20. The clamping portion 241, with the same flat surface as the base portion 242, extends in a direction away from the printed circuit board 20 and receives, clamps, and electrically connects the electrode 12 of the electric motor 10 perpendicular to the board surface of the printed circuit board 20. The flat surface of the plate-shaped electrode 12 received by the clamping portion 241 is approximately parallel to the flat surfaces of the board mounting portion 210 and the facing portion 230.

When assembling an electric motor 10 with a printed circuit board 20 having a connector 200 configured as described above, variations between components can accumulate at the joint between the connector 200 and the electrode 12, causing positional or angular misalignment. Figure 6 shows how the connector 200 absorbs the stress caused by such misalignment, reducing the risk of damage to the electrical joint. As shown by the arrows, if the flat electrode 12 is misaligned laterally relative to the terminal portion 240 (misalignment perpendicular to the flat surface of the board mounting portion 210 and the facing portion 230) or rotated (misalignment from the perpendicular to the flat surface of the terminal portion 240), the terminal portion 240 will move in response to the misalignment of the electrode 12, as indicated by the L-shaped dotted line, and the facing portion 230, connected at end 23E1, will also move accordingly.

Since the board mounting portion 210 is attached by inserting multiple protrusions into holes in the printed circuit board 20, it does not move, and so it is the standing portion 220 that absorbs this movement. Because the facing portion 230 is supported by end 22E1 of the standing portion 220, this movement of the terminal portion 240 and facing portion 230 appears as a rotational movement approximately parallel to the board surface, centered on end 22E1. This occurs because there is a certain distance between end 23E1 of the facing portion 230 and end 22E1, which is the connection point between the facing portion 230 and the standing portion 220, and a moment is generated at end 23E1. Because the width of the standing portion 220 is smaller than the length of the facing portion 230, this movement is mainly caused by twisting of the standing portion 220. The length from end 22E1 to end 23E1, which is the connection portion of facing portion 230 with standing portion 220, the width of standing portion 220, and the total length from the connection portion with board mounting portion 210 to end 22E1 are determined appropriately based on the plate thickness and elasticity of connector 200. Of course, because connector 200 is formed from a conductive plate, some deformation and stress occur not only in standing portion 220 but also in terminal portion 240, facing portion 230, and board mounting portion 210.

In this way, the board mounting portion 210 receives, via the opposing portion 230 and the upright portion 220, force that may arise from misalignment in position or angle when the electrode 12 of the electric motor 10 is press-fit into the terminal portion 240. This makes it easier for the position of the terminal portion 240 to match the position of the electrode 12 of the electric motor 10, and also distributes stress, reducing the force applied to specific locations. This provides a connector 200 that tolerates misalignment in position or angle of the connector 200 on the printed circuit board 20 relative to the electrode 12 of the electric motor 10, reducing the risk of deformation of the connector 200 or damage to the electrical connection with the printed circuit board 20. Furthermore, by providing a three-dimensional upright portion 220 as a stress-absorbing mechanism rather than just in the direction of the printed circuit board, the area occupied by the connector 200 on the printed circuit board of an ECU, which requires a high level of integration, can be reduced.

The board mounting portion 210 has a first protrusion 211, a second protrusion 212, and two third protrusions 213 on one end 21E1 of its flat surface. These protrusions have a diameter similar to the thickness of the board that allows them to be inserted into holes in the printed circuit board 20. The first protrusion 211 and the second protrusion 212 are located on the side closer to the end 23E1 of the facing portion 230, i.e., closer to the terminal portion 240, from the connection portion with the standing portion 220, while the two third protrusions 213 are located on the opposite side, away from the terminal portion 240. The first protrusion 211 is located farthest from the connection portion with the standing portion 220, i.e., almost at the edge of the board mounting portion 210, and the second protrusion 212 is located closer to the connection portion with the standing portion 220 than the first protrusion 211, i.e., between the first protrusion 211 and this connection portion.

The first protrusion 211 and second protrusion 212 are inserted into and soldered to through-holes 21 located at corresponding positions on the printed circuit board 20 (Figures 3 and 5). However, only the first protrusion 211 is electrically connected to the circuit on the printed circuit board 20; the second protrusion 212 is soldered to the through-hole 21 and firmly fixed, but is not connected to the circuit. The third protrusion 213 is inserted into a non-through-hole 22 located at a corresponding position, fits loosely into it, and is not soldered. Note that although there are two third protrusions 213 in this embodiment, there may be only one.

The first protrusion 211 and second protrusion 212, located on one side of the connection between the board mounting portion 210 and the upright portion 220, are soldered to the through-hole 21 (21H in Figure 6) and firmly secured thereto. Meanwhile, the third protrusion 213, located on the other side opposite the connection, is not soldered but fits loosely into the non-through-hole 22, allowing it to move slightly when subjected to force from the connection with the upright portion 220. This allows the board mounting portion 210 to deform slightly between the second protrusion 212 and the third protrusion 213. In response to force from the connection with the upright portion 220, the greatest stress is generated between the connection and the second protrusion 212 in the board mounting portion 210. However, because the second protrusion 212 is firmly secured but not connected to the circuit, even if the solder securing the second protrusion 212 to the through-hole 21 is damaged, the electrical connection between the connector 200 and the printed circuit board 20 is not affected. The joint between the first protrusion 211 and the through hole 21 is firmly fixed in a position farther away from the force applied by the connection than the firmly fixed second protrusion 212, making it less likely to break.

In this way, by configuring the first protrusions 211, which are electrically connected to the circuitry of the printed circuit board 20, to be less susceptible to stress, a printed circuit board 20 is provided that allows for misalignment of the position and angle of the connector 200 on the printed circuit board 20 relative to the electrodes 12 of the electric motor 10, reducing the risk of deformation of the connector 200 or damage to the electrical joints.

In this embodiment, the first protrusion 211 and the second protrusion 212 are located on the side closer to the terminal portion 240 from the connection portion with the standing portion 220, and the third protrusion 213 is located on the opposite side. However, conversely, the first protrusion and the second protrusion may be located on the side opposite the terminal portion from the connection portion with the standing portion, and the third protrusion 213 may be located closer to the connection portion. Even in this case, the first protrusion is located at the farthest position from the connection portion with the standing portion, and the second protrusion is located between the first protrusion and the connection portion and is firmly fixed.

Furthermore, it is preferable that the board mounting portion 210 has a board mounting portion notch 214, which is a curved cutout near the connection portion with the standing portion 220 and extends toward the first protrusion 211, i.e., in the corner of the connection portion on the first protrusion 211 side. By providing the notch 214 in the corner of the connection portion with the standing portion 220, the board mounting portion 210 has a longer path for absorbing stress to the first protrusion 211, which is electrically connected, allowing for misalignment and further reducing the risk of deformation of the connector 200 or damage to the electrical joint. Furthermore, if the first and second protrusions are located on the opposite side of the connection portion with the standing portion from the terminal portion, the board mounting portion notch is formed in the opposite direction from the board mounting portion notch 214 in this embodiment, i.e., in the corner on the first protrusion side of the connection portion. This lengthens the path for absorbing stress to the first protrusion, which is electrically connected.

Furthermore, it is preferable that the facing portion 230 has a facing portion notch 234 that is a curved cutout near the connection portion with the standing portion 220 and extending toward the end portion 23E1, i.e., at the corner on the side extending from the end portion 22E1. In this way, by having a notch 234 at the corner of the facing portion 230 where it connects with the standing portion 220, the path for absorbing stress is lengthened, misalignment is tolerated, and the risk of deformation of the connector 200 or damage to the electrical joint can be further reduced.

Furthermore, it is preferable that the underside 24E1 of the base 242, which forms the underside of the terminal portion 240, abuts against the surface of the printed circuit board 20 when attached. By having the underside of the terminal portion 240 abut against the surface of the printed circuit board 20, displacement of the electrode 12 of the electric motor 10 in the press-fit direction into the terminal portion 240 is minimized, reducing the risk of deformation of the connector 200 or damage to the electrical joint.

As described above, the electric motor module 100, which includes a printed circuit board 20 equipped with a connector 200, can tolerate misalignment of the position and angle of the connector 200 on the printed circuit board 20 relative to the terminals (electrodes 12) of the electric motor 10, reducing the risk of deformation of the connector 200 or damage to the electrical joints.

The present invention is not limited to the illustrated examples, but can be implemented in configurations that do not deviate from the scope of the claims. In other words, while the present invention has been particularly illustrated and described primarily with reference to specific embodiments, those skilled in the art can make various modifications to the above-described embodiments in terms of quantity and other details without departing from the scope of the technical concept and purpose of the present invention.

100 Electric motor module 10 Electric motor 11 Rotating shaft 12 Electrode (mating terminal)
20 Printed circuit board 21 Through hole (first hole)
21H Soldering 22 Non-through hole (second hole)
23 External cable connector 24 Electronic component 30 Gear 31 Final output shaft 40 Storage section 50 Connector storage section 200 Connector 210 Board mounting section 211 First protrusion 212 Second protrusion 213 Third protrusion 214 Board mounting section notch (second notch)
21E1 One end 21E2 Other end 220 Standing part 22E1 End 230 Opposing part 23E1 End 234 Opposing part notch (first notch)
240 Terminal part 241 Clamping part 242 Base part 24E1 Bottom surface

Claims (6)

A connector formed of a conductive plate that is provided on a printed circuit board on which a circuit is provided and that electrically connects the circuit to a mating terminal,
a board mounting portion having a plurality of protrusions at one end thereof to be inserted into holes provided in the printed circuit board;
an upright portion extending from a part of the other end of the board mounting portion in a direction away from the printed circuit board, bending midway, and extending in a direction toward the printed circuit board;
an opposing portion extending from an end of the erected portion substantially parallel to the printed circuit board so as to face the board mounting portion;
a terminal portion connected to an end portion of the opposing portion at a lower portion thereof, and adapted to receive, clamp, and be electrically connected to the mating terminal from a direction perpendicular to the board surface of the printed circuit board;
A connector comprising: The connector described in claim 1, characterized in that the underside of the terminal portion abuts against the surface of the printed circuit board. A connector as described in claim 1 or 2, characterized in that the connection between the facing portion and the standing portion has a first notch at the corner on the side where the facing portion extends from the end of the standing portion. The plurality of protrusions provided at the one end include:
a first protrusion provided at a position on one side and farthest from a connection portion with the standing portion at the other end;
a second protrusion provided on the one side of a connection portion with the standing portion at the other end and at a position closer than the first protrusion;
at least one third protrusion provided on the other side from a connection portion with the standing portion at the other end;
It consists of
4. The connector according to claim 1, wherein a second notch is provided at a corner on the one side of the connecting portion between the board mounting portion and the standing portion. A printed circuit board on which the connector according to claim 4 is mounted,
a first hole at a position corresponding to the first protrusion and the second protrusion, and a second hole at a position corresponding to the third protrusion;
the first protrusion is inserted into the first hole and soldered to the first hole, and is connected to the circuit;
the second projection is inserted into the first hole and soldered, and is not connected to the circuit;
the third protrusion is inserted into and fitted to the second hole and is not soldered;
A printed circuit board characterized by: An electric motor;
The printed circuit board according to claim 5, which receives electric power from an external source and supplies the electric power to the electric motor;
a gear that outputs the power of the electric motor;
a housing portion that houses the electric motor, the printed circuit board, and the gear;
Equipped with
The terminal portion is electrically connected to a terminal of the electric motor.
Electric motor module.