SURFACE-MOUNTABLE (SMD) THERMOCOUPLE CONNECTOR WITH REVERSE POLARITY PROTECTION

Abstract

A connector to easily and correctly join an electrical component to a printed circuit board is provided. The connector comprises a generally C-shaped electrically conductive element that provides for connection alternatively to the positive and negative terminals of a device depending on the orientation of the connector. In this way, one connector is made that can be used to alternatively satisfy connection to both positive and negative terminals and thereby simplify the construction of the element. Because of the shapes of the ends of the connector, a device can only be plugged in one way. The connector can be made from a single sheet of electrically conductive material bent generally into a C shape, with specific tabs and cuts made therein. The connector includes a tab that allows for quick and automated connection to a printed circuit board, and an element to prevent connectors from interlocking while in a loose and unconnected state as, during manufacturing, plating, or storage, allowing them to be added to a board using automated procedures for quick, accurate and low cost construction.

Claims

1. A connector element comprising: a single sheet of electrical conductive material folded to form a generally tubulated element; the generally tubulated element having an elongated axis having a first and second end each formed such that the first end is formed to fit a positive electrical connector and the second end is formed to fit a negative electrical connector; the generally tubulated element comprising a tab to allow for the quick attachment of the generally tubulated element to a printed circuit board.

2. The connector element of claim 1, wherein the electrical conductive material is beryllium-copper and is plated with nickel.

3. The connector element of claim 1, wherein the sheet of electrically conductive material is folded into a generally C-shaped form.

4. The connector element of claim 1, wherein the generally tubulated element is generally C-shaped.

5. The connector element of claim 1, wherein two electrical connectors are placed in a generally parallel relationship, in a reverse axis configuration, to form a junction socket for an electrical device.

6. The connector element of claim 5, where the placement of the connectors forms a poka-yoke connection for polarity protection.

7. The connector element of claim 1, wherein the generally tubulated element comprises a tab, projecting out from the top of the connector element, generally perpendicular to the elongated axis, to prevent two or more connection elements from inter-tangling with each other.

8. A method of providing connection for an electrical device to a printed circuit board including the steps of: forming a pair of generally tubulated elements from electrically conductive material, the generally tubulated elements each having a long axis the ends of the generally tubulated elements being formed such that at one end of each of the axes the generally tubulated element is formed to fit a positive prong of a plug and at the other end of each of the axes the generally tubulated element is formed to fit a negative prong of a plug; and, attaching and electrically linking each of the tubulated elements, in generally parallel configuration and reverse polarity, to the printed circuit board to form a socket connector; wherein, the electrical device can be plugged into one end of each of the generally tubulated elements and be in electrical connection with the printed circuit board.

9. The method according to claim 8, wherein the electrical conductive material is beryllium-copper and is plated with nickel.

10. The method according to claim 8, wherein the tubulated elements are each folded into a generally C-shaped form.

11. The method according to claim 8, where the pair of generally tubulated elements is three tubulated elements.

12. The method according to claim 8, wherein each tubulated element comprises a tab for aid in connection/orientation within a printed circuit board.

13. The method according to claim 8, wherein each tubulated element comprises a tab projecting out from the connector element, generally perpendicular to the elongated axis, to prevent two or more connection elements from inter-tangling with each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of a connector of the prior art.

[0014] FIG. 2 is a perspective view of a second connector of the prior art in place on a circuit board.

[0015] FIG. 3 is an exploded perspective view of a connector of the prior art being placed on a circuit board.

[0016] FIG. 4 is an elevational view of a connector of the present invention.

[0017] FIG. 5 is a perspective view of a connector of the present invention.

[0018] FIG. 6 is a plan view of connectors of the present invention, partially cut away to show placement of a device therein, in place on a printed circuit board and connected to an external device.

[0019] FIG. 7 is a perspective view of the connectors of the present invention in place on a printed circuit board and connected to an external device.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENT

[0020] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings a number of presently preferred embodiments that are discussed in greater detail hereafter. It should be understood that the present disclosure is to be considered as an exemplification of the present invention, and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this application (Detailed Description of the Illustrative Embodiment) relates to a requirement of the United States Patent Office, and should not be found to limit the subject matter disclosed herein.

[0021] Referring to the drawing figures, a connector of the prior art is shown in a perspective view in FIGS. 1 and 2. It will be seen that devices 10 in FIG. 1 comprises folded material having electronic conductivity and means to connect to a printed circuit board and form a connection therewith with an outside device, such as a thermocouple, which when connected will form a device that can be used to measure such things as temperature of third products by taking the measurement of temperature and providing information to the circuit board, for discernment by the devices making up the circuit board. The devices 10 in FIG. 1 are identical Pax connectors shown in reverse configuration next to each other, so that it can be seen that the opening 2 of each connector are identical and by design can incorporate any sized prong, either different widths or identical widths, in either sides opening, leading to, at times, incorrect polarity with the device there plugged. The Pax device 10 includes tabs 4 that allow the device to be placed on a circuit board. The device 10 of FIG. 2 comprises metal elements 12, attached to a printed circuit board 14 allowing the flow of electrons from a male thermocouple connector. 16 to the circuit board 14 for measurement by elements making up the circuit board 14 and for display on any type of display device. The device 10, as shown in FIG. 3, is a more complex connector still in use that comprises elongated connector elements 18 that are pushed through opening 20, in circuit board 14, so that the device 10 can be attached, to the circuit board 14, typically by soldering. It will be understood by persons having ordinary skill in the art that such connection, in the prior art, is made by making openings in the board, pushing the device into the board and hand soldering the device onto the board and into electronic communication with the board. Such processes take an extraordinary amount of time and the use of skilled workers to create a proper and long lasting connection on a circuit board. Connector 10 is a complex element that further includes openings 22 into which an external instrument, such as a thermocouple, can be plugged into. It will be seen that openings 22 are differentiated by size so that a plug can only be plugged in one way.

[0022] Referring now to FIGS. 4 and 5, two views of the device 30 of the present invention are shown. FIG. 4 shows the device 30 in an elevational view. In a preferred embodiment, device 30 is created from a single sheet of electrically conductive material; in the preferred embodiment the material is an amalgam of beryllium and copper that is nickel platedwhich allows excellent conductivity, allows the bending and forming of the desired shape and is resistant to corrosion. It will be understood that numerous other materials, amalgamations, alloys and other material types, can be substituted herein without departing from the novel scope of the present invention. In FIG. 5, a perspective view of device 30, it can be more clearly seen that the final product of the bending of the sheet of electrically conductive material is a generally C-shaped element, having a top wall 32, a bottom wall 34 and a sidewall 36, generally forming a C-shape. Depending from bottom wall 34, and extending generally perpendicular thereto, is a connection tab 38, which is used to fix the position of device 30 on a printed circuit board, for a pick and place automated installation, in a manner known to persons having ordinary skill in the art. Disposed from top wall 32, and extending generally perpendicular thereto, is a larger tab 40, which is provided to keep device 30 free from entanglement with other devices 30.

[0023] The device 30, as illustrated in FIG. 5, clearly shows that, when viewed in the direction of the figure, the left side 42 and right side 44 of device 30 are created with different top members 42t and 44t. It will be seen, that top member 42t comprises a central curved section 42c depending from top 32 and two end members 42e that also depend from top 32 but are angled more severely (and, as shown in FIG. 4, are made to touch the top 34t of bottom wall 34). Top member 44t, in contrast, is a one-piece element, curved similarly to the central curved section 42c. Each device 30 is made in this way to provide, in one element, a connector for both a positive and a negative terminal of an electronic instrument, as will be described in more detail below. Because of the differences in top members 42t and 44t, when assembled correctly in pairs (or other configurations, including the use of three connectors in a three-wire system) the one device 30 can accommodate differing prongs of the electronic element, in the manner that the prior art device 10 (in FIG. 3) does with elements 22.

[0024] Referring now to FIGS. 6 and 7, there is shown the use of devices 30 in combination on a circuit board 14. FIG. 6 shows an electronic element 50 in place within devices 30; so as to more clearly demonstrate the shape and sizes of connective prongs 52, in relation to devices 30, devices 30 are shown partially cut away (please compare same structures in FIG. 7) so that the relative sizes of the prongs 52 can be better shown relative thereto. It will be seen in FIG. 6, that negative prong 52n has a greater width than positive prong 52p has; which is a standard configuration of negative and positive prongs on such elements. In this manner, the user of the devices 30 can only plug electronic elements 50 into circuit boards 14, which have the devices of the present invention thereon, one way (that is, turning element 50 upside down and trying to plug prongs 52n, 52p into devices 30, will not work due to the sizes of the prongs and the concomitant sizes of the openings in devices 30); this is to protect the element 50 and the board 14 from the deleterious effects of accidently reversing the polarity of either. As is demonstrated in FIG. 6, when viewed with FIG. 5, the larger width prong 52n can only fit into the right side element 44 that has the large opening therein and the more narrow width prong 52p, which could be placed in either side, is more well suited to be placed into the left side element 42, which has leg elements 42e to help create a snug fit within device 30 for prong 52p and create a barrier to the incorrect introduction of wide prong 52n therein. In this way, a connector made of two devices 30 in a reverse orientation to each other, forms a socket 60 for the plug element of element 50. It will be understood that with one element, device 30, any configuration of plug can be formed with the correct number of individual devices 30 oriented alongside each other as needed to accommodate the number of prongs from the device. It will be understood by persons having ordinary skill in the art that the device of the present invention covers all SMT mountable Thermocouple connectors that incorporate an asymmetrical design to ensure reverse polarity protection. It should also be understood, that the device is not exclusive to thermocouples but can be used for all electrical based temperature sensors, including RTDs and Thermistors, as well.

[0025] FIG. 7 shows the connection of the electronic element 50 with the socket 60 of the present invention. Prong 52p is clearly shown fitting into side 42, with prong 52p held tightly, and in electrical communication, therein by end members 42e and prong 52n is shown held within the top 44t and bottom 34 of end 44, in electronic communication; all to form an electrical circuit connecting element 50 to circuit board 14. Each device 30 is shown in place in reverse orientation from the other device 30, which form socket 60, so as to show that with a single style of element 30, thereby simplifying the process of making such devices in that only one design is needed to accomplish the designated purpose, is used to create the attachment point for a circuit board.

[0026] Because only one type of device 30 is needed, manufacturing is simplified and the process of creating printed circuit boards using such elements is simplified and accelerated. Fewer errors are made and better boards are produced in a more completely automated manner, thereby increasing production ability as well as providing cleaner and less buggy operations.

[0027] In specific summary then, the invention is a Surface Mountable Thermocouple Connector with reverse polarity protection (PCC-SMD). Though the primary application is for Thermocouple sensors, it is not exclusive to thermocouples. The design of the invention can be used for all electrical based temperature sensors, including Resistance Temperature Detectors (RTDs) and Thermistors. Similar to the prior and no longer available PAX art, this Thermocouple Connector is a Surface Mountable Device, meaning it is automation-ready for standard pick-and-place machines/PCB automation. This SMD style thermocouple connector will save the PCB manufacturer labor and cost, making it very attractive for high-volume applications. The present invention has at least three primary improvements over existing connectors, among these are:

[0028] 1) The present invention provides reverse polarity protection, making it error-proof (poka-yoke). The PCC-SMD is designed with specific features with mechanical blocking so that the user is not able to plug the mating Thermocouple connector in backwards or upside down. This device of the invention is asymmetric and ensures that the PCB manufacturer must mount the connector in the fashion that the PCB designer intended.

[0029] 2) A secondary improvement is that the device of the present invention can be made much slimmer in height than prior existing devices. The existing device disclosed above is 3.27 mm in height, whereas the device of the present invention is, in a preferred embodiment, 2.36 mm at its maximum point (a 28% reduction in height, with the same footprint). This is notable because this allows for thinner electronics and tighter PCB packing within casing, which is important in the advancing electronics industry.

[0030] 3) A tertiary improvement is that the present invention incorporates only 2 primary bends, resulting in simple c shaped geometry, whereas the existing device disclosed above has 4 primary bends, resulting in e shape geometry. The existing device, therefore, requires 55% more raw material, as well as much more complex tooling to be made. This results in the device of the present invention being much more easily manufacturable and also more economical to make.

[0031] Although an illustrative embodiment of the invention has been shown and described, it is to be understood that various modifications and substitutions may be made by those skilled in the art without departing from the novel spirit and scope of the invention.