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Title:
CONNECTOR ASSEMBLY FOR ELECTRICALLY CONNECTING AN ELECTRICAL DEVICE WITH ELECTRICAL CONNECTION MEANS
Document Type and Number:
WIPO Patent Application WO/2020/260490
Kind Code:
A1
Abstract:
The invention relates to a connector assembly (1) for electrically connecting an electrical device (2) with electrical connection means (3), wherein the connector assembly (1) comprises at least one conductive pad (4) electrically connected with the electrical connection means (3) and at least one electrical connector (5) preferably having a connector pin, said at least one electrical connector (5) being configured to be pierced trough a cover element (12) or a shield such as to electrically connect the electrical device (2) with the at least one conductive pad (4).

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Inventors:
SELVINI FRÉDÉRIC (FR)
WELTER PATRICK (FR)
ZOSSI DORIAN (FR)
PICK GAËTAN (FR)
Application Number:
PCT/EP2020/067889
Publication Date:
December 30, 2020
Filing Date:
June 25, 2020
Export Citation:
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Assignee:
DAIMAY FRANCE SAS (FR)
International Classes:
B60J3/02
Foreign References:
DE10340079A12005-04-14
JPH0853010A1996-02-27
US3383641A1968-05-14
Attorney, Agent or Firm:
TRINKS, Ole (DE)
Download PDF:
Claims:
Claims

1. Connector assembly (1) for electrically connecting an electrical device (2) with electrical connection means (3), wherein the connector assembly (1) comprises at least one conductive pad (4) electrically connected with the electrical connection means (3) and at least one electrical connector (5) preferably having a connector pin, said at least one electrical connector (5) being configured to be pierced trough a cover element (12) or a shield such as to electrically connect the electrical device (2) with the at least one conductive pad (4).

2. Connector assembly (1) according to Claim 1,

wherein the at least one conductive pad (4) comprises a terminal with a plurality of contact holes, each contact hole being adapted to receive said at least one electrical connector (5) such as to electrically connect the electrical device (2) with the electrical connection means (3).

3. Connector assembly (1) according to Claim 1 or 2,

wherein the at least one conductive pad (4) comprises a grid structure made of a conductive material and electrically connected with the electrical connection means (3), wherein a plurality of contact holes is formed by the grid structure, each contact hole being adapted to receive said at least one electrical connector (5) such as to electrical connect the electrical device

(2) with the electrical connection means (3).

4. Connector assembly (1) according to one of Claims 1 to 3,

wherein the at least one conductive pad (4) comprises a grid structure having a grid interstice that is just same or smaller as the size of the electrical connector (5) and, in particular, the size of the connector pin of the electrical connector (5).

5. Connector assembly (1) according to one of Claims 1 to 4,

wherein the at least one conductive pad (4) comprises at least one conductive wire electrically connected with the electrical connection means

(3), said at least conductive wire being aligned in a zig-zag pattern.

6. Connector assembly (1) according to Claim 5,

wherein the at least one conductive pad (4) has a plurality of hook holes formed on a surface of the conductive pad (4) by puncturing, wherein the conductive wire is inserted and bound in a zig-zag pattern into the hook holes.

7. Connector assembly (1) according to one of Claims 1 to 6,

wherein the at least one electrical connector (5) comprises a fixing means, preferably a hook, to prevent the electrical connector (5) from separating from the at least one conductive pad (4).

8. Component that is designed for use in a vehicle, comprising a structural part (11) and a cover element (12), the cover element (12) being connected to the structural part (11) preferably by a removable

connection, wherein the structural part (11) is provided with electrical connection means (3), preferably a wire harness (6) comprising a pattern of electrical connections, and wherein the component further comprises an electrical device (2) and a connector assembly (1) according to one of claims 1 to 7 for electrically connecting the electrical device (2) with the electrical connection means (3). 9. Component according to Claim 8,

wherein the electrical connection means (3) comprises a wire harness (6) electrically connected with the at least one conductive pad (4) of the connector assembly (1), said wire harness (6) electrically connecting said at least one conductive pad (4) with a plug connector that is preferably arranged outside the component.

10. Component according to Claim 8 or 9,

wherein said at least one electrical connector (5) of the connector assembly (1) is pierced through the cover element (12) of the component to reach the at least one conductive pad (4).

11. Component according to one of Claims 8 to 10,

further comprising a decorative material overlaying at least a portion of the cover element (12).

12. Component according to one of Claims 8 to 11,

wherein the electrical device (2) preferably comprises at least one light source, in particular LED, at least one electrical actuator, and/or at least one heating element.

13. Component according to Claim 12,

wherein the electrical device (2) is part of an accessory component to be mounted to the structural part (11) or the cover element (12) of the component.

14. Component according to one of Claims 8 to 13,

wherein the component is a sun visor (10) designed for use in a vehicle, and wherein the electrical device (2) comprises illumination means of a vanity mirror (13) received in a mirror region (14) of the cover element (12).

15. Sun visor (10) for use in a vehicle, comprising:

a structural part (11);

a cover element (12), in particular a covering sheet made preferably of a plastic material such as polyvinyl chloride; and a vanity mirror (13) having illumination means, said vanity mirror (13) being received by a mirror region (14) of the cover element (12), wherein the structural part (11) of the sun visor (10) is provided with electrical connection means (3), preferably a wire harness (6) comprising a pattern of electrical connections, and wherein the vanity mirror (13) comprises at least one electrical light source, wherein the sun visor (10) further comprises at least one connector assembly (1) according to one of claims 1 to 7 for electrically connecting the electrical light source of the vanity mirror (13) with the electrical connection means (3) of the structural part (11) of the sun visor (10).

16. Sun visor (10) according to Claim 15,

further comprising a decorative material overlaying at least a portion of the cover element (12).

17. System comprising an electrical device (2), a sun visor assembly with

electrical connection means (3) and with at least one conductive pad (4) electrically connected with the electrical connection means (3), and at least one electrical connector (5), wherein the at least one electrical connector (5) is pierced trough a cover element (12) of the sun visor assembly to electrically connect the electrical device (2) with the at least one conductive pad (4).

18. Method for producing a component for use in a vehicle, in particular a sun visor (10), comprising:

providing a structural part (11) and a cover element (12);

arranging the cover element (12) and the structural part (11) relative to one another and connecting the cover element (12) to the structural part (11) preferably by a connecting movement;

providing an accessory component having an electrical device (2) and arranging the accessory component relative to the cover element (12) and the structural part (11);

connecting the accessory component to the cover element (12) and/or the structural part (11),

wherein during connecting the accessory component to the cover element (12) and/or the structural part (11), at least on electrical connector (5) of the electrical device (2) is pierced trough the cover element (12) to electrical connect the electrical device (2) with at least one conductive pad (4) of electrical connection means (3) arranged at the structural part (11).

Description:
CONNECTOR ASSEMBLY FOR ELECTRICALLY CONNECTING AN

ELECTRICAL DEVICE WITH ELECTRICAL CONNECTION MEANS

Description

This invention generally relates to connector assemblies for electrically connecting an electrical device with electrical connection means. Moreover, this invention relates to components that are designed for use in a vehicle, for example, sun visor assemblies, wherein the components are provided with connector assemblies for electrically connecting an electrical device with corresponding electrical connection means.

Components, such as sun visors, which are used in particular in the interior of a vehicle, are generally known. It is desirable that they be lightweight and cost- effective. On the other hand, it is also desirable that their assembly be cost- effective and they have a long service life, during which they are sometimes subjected to extreme situations with regard to temperature conditions and with regard to oscillating and/vibrating conditions. Furthermore, at the end of their useful life, it is desirable that such components be easily accessible to material utilization (recycling). Also, it is desirable that such components be designed to be aesthetically attractive. Which such known components, it is common for electrical devices to be used in the components. Such electrical devices may comprise light sources, in particular LEDs, and/or electrical actuators and/or heating means.

Interior components, for example, sun visors, are currently installed in the interior of motor vehicles and a series of steps at a plurality of stations on a vehicle assembly line. Individual interior components that require electricity as a power source or to provide a signal are individually connected to the vehicle body electrical system at the time of assembly.

A wire harness, including all of the wiring necessary for the interior component, is attached to a structure part of the component with, for example, tape or hot melt glue. The various wires forming the wire harness are typically located between the structural part of the interior component and a cover element of the component. For electrically connecting an electrical device with the wi res forming the wire harness an connection space must be formed by cutting or opening corresponding holes in the cover element. However, to free the connection space by cutting or opening holes, the connector's position must be detected precisely which requires time and money in the assembly process. This is particularly the case if the wire harness or the component to link electrically is not visible or not always at the same position in front of the component to assemble.

The object of the invention, therefore, is to provide a way to connect electrically an electrical device of a component that is designed for use in a vehicle interior, allowing some relative position dispersion between the electrical device and the component, without any additional operation of cutting and/or positioning.

In particular, the present invention concerns a way to connect electrically some components of a sun visor, allowing some relative position dispersion between these components. This function is really useful when the target is not visible or not always at the same position in front of the element to assemble.

These objects are achieved according to the embodiments of the invention by a connector assembly for electrically connecting an electrical device with electrical connection means, wherein the connector assembly comprises at least one conductive pad electrically connected with the electrical connection means and at least one electrical connector preferably having a connector pin, said at least one electrical connector being configured to be pierced through a covering layer, a covering sheet, or any other shield such as to electrically connect the electrical device with the at least one conductive pad.

According to the embodiments of the invention, it is preferred that the at least one conductive pad comprises a terminal with a plurality of contact holes, each contact hole being adapted to receive said at least one electrical connector (in particular the connector pin of the at least one electrical connector) such as to electrically connect the electrical device with the electrical connection means.

It is further advantageous if the at least one conductive pad comprises a grid structure made of a conductive material and electrically connected with the electrical connection means, wherein the plurality of contact holes is formed by the grid structure, each contact hole being adapted to receive said at least one electrical connector such as to electrically connect the electrical device with the electrical connection means. Preferably, the grid structure has a grid interstice that is just the same or smaller as the size of the electrical connector and, in particular, the connector pin of the electrical connector.

It is furthermore advantageous if the at least one conductive pad comprises at least one conductive wire electrically connected with the electrical connection means, said at least one conductive wire being aligned in a zig -zag pattern. The at least one conductive pad may have a plurality of hook holes formed on the surface of the conductive pad by puncturing, wherein the conductive wire is inserted and bound in a zig-zag pattern into the hook holes.

It is further preferred that the at least one electrical connector comprises fixing means, preferably a hook, to prevent the electrical connector from separating from the at least one conductive pad.

According to another aspect of the present invention, the object underlying the present invention is achieved according to the embodiments of the invention by a component that is designed for use in a vehicle, wherein the component comprises a structural part and the cover element, the cover element being connected to the structural part preferably by a removable connection, wherein the structural part is provided with electrical connection means, preferably via harness comprising a pattern of electrical connections, and wherein the component further comprises an electrical device and a connector assembly according to the above-summarized part for electrically connecting the electrical device with the electrical connection means.

According to a particularly preferred embodiment of the inventive component, the electrical connection means comprises a wire harness electrically connected with the at least one conductive pad of the connector assembly, said wire harness electrically connecting said at least one conductive pad with a plug connector that is preferably arranged outside the component.

It is further preferred that said at least one electrical connector of the connector assembly is pierced through the cover element of the component to reach the at least one conductive pad. In this regard, it is important to note that the component may further comprise a decorative material or decorative layer overlaying at least a portion of the cover element.

The electrical device preferably comprises at least one lig ht source, in particular LED, at least one electrical actuator, and/or at least one heating means.

According to some embodiments of the present invention, the electrical device is part of an accessory component to be mounted to the structure part or the cover element of the component. For example, the component may be a sun visor designed for use in a vehicle, wherein the electrical device comprises illumination means of a vanity mirror that is received by a mirror region of the cover element of the component.

According to a further aspect, the present invention relates to a sun visor for use in a vehicle, comprising a structural part, a cover element, in particular a covering sheet made preferably of plastic materials such as polyvinyl chloride, and a vanity mirror having illumination means. The vanity mirror is received in a mirror region of the cover element of the sun visor. The structure part of the sun visor is provided with electrical connections means, for example, a wire harness comprising a pattern of electrical connections attached to the structure part. The vanity mirror comprises at least one electrical light source that is connected with the electrical connection means of the structure part by using at least one electrical connector preferably having a connector pin that is pierced through the cover element of the sun visor such as to electrically connect the electrical light source with at least one conductive pad of the electrical connection means arranged at the structure part of the sun visor.

According to a particularly preferred embodiment of the inventive sun visor, the sun visor further comprises a decorative material, in particular, a decorative layer overlaying at least a portion of the cover element.

According to a further aspect of the present invention, the object underlying the invention is achieved by a system comprising an electrical device, a sun visor assembly with electrical connection means and with at least one conductive pad electrically connected with the electrical connection means, and at least one electrical connector preferably having a connector pin, wherein the at least one electrical connector is pierced through a cover sheet of the sun visor assembly to electrically connect the electrical device with the at least one conductive pad.

According to a further aspect, the present invention relates to a method for producing a component for use in a vehicle, in particular a sun visor. The method comprises the step of providing a structure part in the cover element, and the step of arranging the cover element and the structure part relative to one another and connecting the cover element to the structure part preferably by a connecting movement. The inventive method further comprises the steps of providing an accessory component having an electrical device and arranging the accessory component relative to the cover element and the structure part, and connecting the accessory component to the cover element and the structure part by a connecting movement. During connecting the accessory component to the cover element, at least one electrical connector of the electrical device is pierced through the cover element to electrically connect the electrical device with at least one conductive pad of electrical connection means arranged at the structure part.

As a result, the manufacturer of vehicle interior components comprising electrical devices may be improved, in particular accelerated and reduced in cost. These and other features and advantages of components according to this invention are described in, or are apparent from, the following detailed descriptions of the exemplary embodiment according to this invention. One exemplary embodiment of the component according to the present disclosure will be described in detail, with reference to the following Figures, wherein:

FIG. 1 is a top view of a sun visor as an example of a component according to an exemplary embodiment of the invention;

FIG. 2 is an exploded view of the sun visor according to FIG. 1;

FIG. 3 is a top view of a structure part of the sun visor according to FIG.

i;

FIG. 4 is a perspective view of electrical connection means arranged at the structure part of the sun visor according to FIG. 1;

FIG. 5 is an exploded view of a vanity mirror assembly of the sun visor according to FIG. 1; and

FIG. 6 is a perspective view of the connector assembly for electrically

connecting the vanity mirror assembly with the electrical connection means arranged at the structure part of the sun visor according to FIG. 1.

A perspective view of a sun visor 10 as shown in FIG. 1 is an example of a component according to some aspects of the present invention.

The sun visor 10 has a cover element 12 which surrounds a mirror region 14 and/or of which the edge region at least partly covers. The mirror may be provided as a vanity mirror 13 or the like and, in particular, may have

illumination.

One exemplary embodiment of a suitable vanity mirror assembly 13 is illustrated in an exploded view in FIG. 5. Moreover, it may be provided that the mirror region 14 and/or the mirror - additionally to the cover element 12 - has a decorative cover not noted further by a reference numeral.

An exploded view is illustrated in FIG. 2 for clarification of the construction of the sun visor 10 and/or the component, in particular at least one molded body (cover element 12) being visible. The sun visor 10 may also comprise a decorative material not illustrated in FIG. 2. The sun visor 10, as an example of the component according to the illustrated embodiment of the invention, may comprise respectively on its upper face and its lower face a decorative material or decorative layer and a molded body acting as cover element 12.

In the example, a structural part 11 is located between the molded bodies forming the cover element 12, on which structural part 11, for example, structural elements of the structural part 11 and electrical connection means 3 and/or leads of the component and/or the sun visor 10 (not denoted further by reference numerals in FIG. 2) are arranged. The presence of an upper face and a lower face on the sun visor 10 is because the sun visor 10 generally has a visible face on both sites, i.e. it is possible for the user to see both the lower face and the upper face, depending on the folded position of the sun visor 10.

This feature, however, does not have to be provided in every component according to the invention in and/or on a vehicle, in particular a motor vehicle.

For example, for components provided for cladding a door or a further component of a vehicle interior, it is possible that said components have only one visible face. In this case, such component could also have only one molded body acting as cover element 12 that may be provided with a decorative material.

Only the other face of the sun visor 10 is described in more detail hereinafter.

The upper face of the sun visor 10 has a cover element 12 formed by a molded body and preferably having a decorative material, the decorative material and , in the illustrated embodiment, also the molded body of the cover element 12 may have an aperture. The aperture in the molded body of the cover element 12 acts as mirror region and is denoted by the reference numeral 14. In the sun visor 10, as an example of a component, the aperture 14 is present, in particular, for the vanity mirror assembly 13 provided on one site. Flowever, with another

component, corresponding apertures could also be used for other purposes.

According to the illustrated embodiment of the invention, the molded body of the cover element 12 has an edge region around the aperture 14, in which the decorative material may be fastened to the molded body so that, for example, no wrinkling of the decorative material occurs. This may, for example, occur by bending back the decorative material or even by means of an additional fastening element.

A top view of the upper face of the sun visor 10 without the cover element 12 is schematically illustrated in FIG. 3 such that the structural part 11 of the sun visor 10 and exemplary elements for providing the electrical and mechanical

functionality of the sun visor 10 is visible. The exemplary elements for providing the electrical and mechanical functionality of the sun visor 10 are all substantially integrated within and/or mounted on the structural part 11 of the sun visor 10.

For example, a sliding cover, a cover spring, a vanity mirror assembly 13, a pivot device, a pivot spring, and electrical connection means 3 are fastened to the structural part 11 of the sun visor 10.

An exploded view is illustrated in FIG. 4 of an exemplary embodiment of the electrical connection means 3 that are substantially integrated within and/or mounted on the structural part 11 of the sun visor 10. According to this exemplary embodiment, the electrical connection means 3 comprises at least one conductive pad 4 electrically connected with a wire harness 6 comprising a pattern of electrical connections. The wire harness 6 electrically connecting the at least one conductive pad 4 with a plug connector 7 that may be provided outside the sun visor 10. The at least one conductive pad 4 may be connected to the electrical connections of the wire harness 6 by crimping or other connection means.

The at least one conductive pad 4 comprises a terminal with a plurality of contact holes, each contact hole being adapted to receive at least one electrical connector 5 preferably in the form of a connector pin such as to electrically connect the electrical connector 5 with the electrical connection means 3 integrated in or arranged at the structural part 11 of the sun visor 10.

In this regard, reference is also made to the exploded view illustrated in FIG. 6 which shows an exemplary embodiment of a connector assembly 1 for connecting an electrical device 2, for example an electrical lighting element of a vanity mirror assembly 13 (see FIG. 5) with the electrical connection means 3 arranged at the structural part 11 of the sun visor 10. The at least one conductive pad 4 of the electrical connection means 3 may comprise a grid structure made of a conductive material and electrically connected with the electrical connections (wire harness 6) of the electrical connection means 3. A plurality of contact holes may be formed by the grid structure, each contact hole being adapted to receive said at least one electrical connector 5 and, in particular, the connector pin of the at least one electrical connector 5 of the electrical device 2 such as to electrically connect the electrical device 2 with the electrical connection means 3.

In an alternative embodiment not illustrated in the drawings, the at least one conductive pad 4 may comprise at least one conductive wire electrically connected with the electrical connection means 3, wherein the at least one conductive wire is aligned in a zig-zag pattern. In this regard, the at least one conductive pad 4 may further comprise a plurality of hook holes formed on a surface of the conductive pad 4 by puncturing, wherein the conductive wire is inserted and bound in the zig-zag pattern into the hook holes.

As illustrated in FIG. 6, the at least one electrical connector 5 of the electrical device 2 preferably comprises at least one connector pin and is configured to be pierced through the cover element 12 of the sun visor 10 or a covering layer of the sun visor 10 such as to electrically connect the electrical device 2 with the at least one conductive pad 4 of the electrical connection means 3 arranged at the structural part 11 of the sun visor 10.

Moreover, the electrical connector 5 may be provided with fixing means, for example, hooks to prevent the electrical connector 5 from separating from the at least one conductive pad 4.

In the illustrated embodiment, the vanity mirror assembly 13 is plugged into the structural part 11 of the sun visor 10 through the cover element 12, which is preferably made of a plastic material, such as polyvinyl chloride. The problem is that when the electrical connector 5 of the vanity mirror assembly 13 is to be electrically connected to the electrical connection means 3 arranged at the structural part 11 of the sun visor 10, the sun visor 10 is already closed by the cover element 12 with no holes to free the connection area. In addition, the relative position of all components can move a little, due to manufacturing and assembly dispersions. This can be a few millimeters more or less than the nominal dimensions.

To solve this problem, the inventive connector assembly 1 is used that allows a "blind" connection. By pushing the vanity mirror assembly 13 with the electrical connector 5 that is a male connector having a connector pin vertically to the structural part 11 of the sun visor 10, the electrical connector 5 of the vanity mirror assembly 13 pierce the cover sheet of the sun visor 10 to come picking anywhere they want into the conductive pad 4 of the electrical connection means 3 of the structural part 11 of the sun visor 10 thereby establishing the electrical contact on each one.

The at least one conductive pad 4 of the electrical connection mains may be formed by a grid structure having a grid interstice that is just smaller as the pin size of the electrical connector 5, as long as a contact is guaranteed between the two components.

In the illustrated embodiment, the electrical device 2 comprises a plurality of light sources, in particular LEDs. The invention, however, is not limited to such light sources. Rather, other embodiments comprise electrical actuators and/or heating means as electrical devices 2.

It should be noted that the references to relative positions (e.g., "top" and "bottom") in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiment illustrated herein.

It should be appreciated that the construction and arrangement of the wire harness 6 and the electrical connection means 3, as shown in the exemplary embodiment, is illustrative only. While the wire harness 6, according to this invention, has been described in conjunction with the exemplary embodiment outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent. Accordingly, the exemplary embodiment of the inventive component (sun visor 10), as said forth above, is intended to be illustrative, not limiting.

List of reference numerals

1 connector assembly

2 electrical device

3 electrical connection means

4 conductive pad

5 electrical connector

6 wire harness/Electrical connection

7 plug connector

10 component/sun visor

11 structural part

12 cover element

13 vanity mirror

14 mirror region




 
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