Insert device for electrical relays, solenoids, motors, controllers, and the like

• US 5,455,734 A
• Filed: 07/01/1993
• Issued: 10/03/1995
• Est. Priority Date: 04/29/1991
• Status: Expired due to Term

• Current Assignee: Northrop Grumman Systems Corporation (Northrop Grumman Corporation)
• Original Assignee: TRW Limited (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Inventors: Miller, Paul J., Kiser, Willie C., Foreman, Kevin G.
• Primary Examiner(s): Hoff, Marc S.
• Assistant Examiner(s): JACKSON, STEPHEN W
• Application Number:
  US08/087,638
• Time in Patent Office: 824 Days
• Field of Search: 361/56, 361/91, 361/111, 361/118, 361/119, 361/127, 361/115, 439/225, 439/608, 439/98, 439/225, 307/9, 307/10
• US Class Current: 361/118
• CPC Class Codes: G06F 21/00 Security arrangements for protecting computers, components thereof, programs or data against unauthorised activity
• CPC Class Codes: H01R 13/6397 with means for preventing unauthorised use
• CPC Class Codes: H01R 13/6616 with resistor
• CPC Class Codes: H01R 13/6625 with capacitive component
• CPC Class Codes: H01R 13/665 with built-in electronic circuit H01R13/70, H01R13/719 take precedence
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/6666 with built-in overvoltage protection
• CPC Class Codes: H01R 29/00 Coupling parts for selective co-operation with a counterpart in different ways to establish different circuits, e.g. for voltage selection, for series-parallel selection, programmable connectors
• CPC Class Codes: H01R 31/065 with built-in electric apparatus
• CPC Class Codes: H01R 9/03 Connectors arranged to contact a plurality of the conductors of a multiconductor cable , e.g. tapping connections
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H05K 1/0231 Capacitors or dielectric substances
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/10053 Switch
• CPC Class Codes: H05K 2201/10424 Frame holders
• CPC Class Codes: H05K 2201/10515 Stacked components
• CPC Class Codes: H05K 2201/1053 Mounted components directly electrically connected to each other, i.e. not via the PCB

Abstract

An insert device employing electronics is non-intrusively disposed between an electronic mechanism'"'"'s pins and female connector in order to provide the mechanism with electronic functional capabilities. The insert device is of a shape, size, and character such that normal mating engagement between the mechanism'"'"'s pins and connector is unaffected.

Claims

1. A device for use with a relay having a plurality of pins which mate with sockets in a female relay connector, said device comprising:

a substrate having holes therein aligned with said pins of said relay, said substrate being insertable over said pins such that said pins extend through the holes, said substrate being sufficiently thin so as to fit between said relay and said female relay connector while permitting mating engagement therebetween;

contact means for contacting at least one of said pins when said pins extend through the holes in said substrate;

electrical component means on said substrate for performing a preselected function on at least one electrical signal carried by at least one of said pins; and

electrically conductive means for coupling said contact means to said electrical component means, whereby said device provides said preselected function on at least one electrical signal carried by at least one of said pins when inserted onto said relay and said relay is mated with said female relay connector.

2. The device of claim 1 wherein said device being removably insertable within an exterior surface area of a casing of said relay, said substrate having a perimeter being substantially located within a perimeter of said relay casing.

3. The device of claim 1 wherein said contact means electrically contacts a coil of said relay through at least one of said pins.

4. The device of claim 1 wherein said conductive means are formed on at least one major surface of said substrate, as an electrical conductor pattern.

5. The device of claim 1 wherein said contact means is on at least one major surface of said substrate and includes a plurality of electrically conductive bendable fingers.

6. The device of claim 1 wherein said substrate is formed from a material selected from a group of dielectric substrates and semiconductor materials.

7. The device of claim 1 wherein said electrical component means includes at least one integrated circuit.

8. The device of claim 1 wherein said preselected function provides suppression of selected voltages carried by at least one of said pins.

9. The device of claim 1 wherein said relay is a simple relay.

10. The device of claim 9 wherein said preselected function provides a timing function for said simple relay.

11. A device, being removably insertable within an exterior surface area of a casing of a simple relay having a plurality of pins which mate with sockets in a female relay connector, said device comprising:

a substrate having upper and lower major surfaces, said substrate having holes therein aligned with said pins of said relay, said substrate being insertable over said pins such that said pins extend through the holes, said substrate having a perimeter being substantially located within a perimeter of said relay casing, said substrate being sufficiently thin so as to fit between said relay and said female relay connector while permitting mating engagement therebetween, said substrate being formed from a material selected from a group of dielectric substrates and semiconductor materials;

a plurality of electrically conductive bendable fingers, being affixed to at least one of said major surfaces, contacting a coil of said relay through at least one of said pins;

electrical component means on said substrate for providing a timing function on at least one electrical signal carried by at least one of said pins of said relay, said electrical component means having at least one component selected from a group of capacitors, diodes, transistors, resistors, analog and digital components, address decoders, integrated circuits, and combinations thereof; and

an electrical conductor pattern, formed on at least one of said major surfaces, for coupling said conductive bendable fingers to said electrical component means, whereby said device provides a timing function on at least one electrical signal carried by at least one of said pins when inserted onto said relay and said relay is mated with said female relay connector.

12. A device, being removably insertable within an exterior surface area of a casing of a relay having a plurality of pins which mate with sockets in a female relay connector, said device comprising:

a substrate having upper and lower major surfaces, said substrate having a perimeter being substantially located within a perimeter of said relay casing, said substrate having holes therein aligned with said pins of said relay, said substrate being insertable over said pins such that said pins extend through the holes, said substrate being sufficiently thin so as to fit between said relay and said female relay connector while permitting mating engagement therebetween, said substrate being formed from an insulating material;

a plurality of electrically conductive bendable fingers, affixed to at least one of said major surfaces, contacting at least one of said pins when said pins extend through the holes in said substrate;

electrical component means on said substrate for suppressing selected voltages carried by at least one of said pins, said electrical component means having at least one component selected from a group of capacitors, diodes, metal oxide varistors, and combinations thereof; and

an electrical conductor pattern coupling said conductive bendable fingers to said electrical component means, whereby said device suppresses selected voltages carried by at least one of said pins when inserted into said relay and said relay is mated with said female relay connector.

13. A voltage suppression device for protecting a relay having a plurality of pins which mate with sockets in a female relay connector, said device comprising:

a structure being sufficiently thin so as to fit between said relay and said female relay connector while permitting mating engagement therebetween, said structure having holes therein aligned with said pins of said relay, said structure being insertable over said pins such that said pins extend through the holes;

first contact means for contacting at least one of said pins when said pins extend through the holes in said structure;

ground plane means for coupling selected voltage signals on at least one of said pins to a ground pin of said relay;

electrical component means, is coupled to said ground plane means, for coupling said selected voltage signals to said ground plane means; and

electrically conductive means for coupling said first contact means to said electrical component means, whereby said device suppresses selected voltages carried by said pins when inserted onto said relay and said relay is mated with said female relay connector.

14. The device of claim 13 wherein said device is removably insertable within an exterior surface area of a casing of said relay, said structure having a perimeter being substantially located within a perimeter of said relay casing.

15. The device of claim 13 wherein said structure further comprises a plurality of component holes extending through said structure for receiving said electrical component means.

16. The device of claim 13 wherein said structure includes a body having opposing first and second faces.

17. The device of claim 16 wherein said first contact means is on said first face and includes a plurality of first bendable fingers.

18. The device of claim 16 wherein said ground plane means is a conductive plate, affixed substantially coextensive to said second face, and includes a plurality of second bendable fingers contacting said ground pin.

19. The device of claim 16 wherein said electrical component means comprises at least one capacitor.

20. The device of claim 16 wherein said body is formed with an insulating material.

21. A voltage suppression device, being removably insertable within an exterior surface area of a casing of a relay having a plurality of pins which mate with sockets in a female relay connector, for protecting said relay, said device comprising:

a structure having a perimeter being substantially located within a perimeter of said relay casing, said structure being sufficiently thin so as to fit between said relay and said female relay connector while permitting mating engagement therebetween, said structure having holes therein aligned with said pins of said relay, said structure being insertable over said pins such that said pins extend through the holes, said structure including a body, being formed from an insulating material, having opposing first and second faces;

a plurality of first bendable fingers, affixed to said first face, contacting at least one of said pins when said pins extend through the holes in said structure;

a conductive plate, affixed substantially coextensive to said second face, having a plurality of second bendable fingers contacting a ground pin of said relay; and

electrical component means on said body and contacting said conductive plate, for coupling selected voltage signals on at least one of said pins to said conductive plate, said electrical component means having at least one component selected from a group of capacitors, diodes, metal oxide varistors, or combinations thereof, said structure further including a plurality of component holes extending through said structure for receiving said electrical component means, whereby said device suppresses selected voltages carried by at least one of said pins when inserted onto said relay and said relay is mated with said female relay connector.

22. An addressable interface insert device for use with an electronically activated mechanism having a plurality of pins which mate with sockets in a female connector and which is activated in response to an address signal, said device comprising:

a substrate having holes therein aligned with said pins of said mechanism said substrate being insertable over said pins such that said pins extend through the holes, said substrate being sufficiently thin so as to fit between said mechanism and said female connector while permitting mating engagement therebetween;

contact means for contacting at least one of said pins when said pins extend through the holes in said substrate;

electrical component means on said substrate for providing address decoding of the address signal carried by at least one of said pins in order to selectively activate said mechanism in response to a predetermined address; and

electrically conductive means for coupling said contact means to said electrical component means, whereby said device decodes the address signal carried by at least one of said pins when inserted onto said pins and said pins are mated with said female connector.

23. The device of claim 22 wherein said mechanism is a solenoid.

24. The device of claim 22 wherein said device is removably insertable within an exterior surface area of a casing of said mechanism, said substrate having a perimeter being substantially located within a perimeter of said mechanism casing.

25. The device of claim 22 wherein said conductive means are formed on at least one major surface of said substrate as an electrical conductor pattern.

26. The device of claim 22 wherein said contact means is a conductive material disposed in side walls defining the holes of said substrate.

27. The device of claim 22 wherein said substrate is formed from a material selected from a group of dielectric substrates and semiconductor materials.

28. The device of claim 22 wherein said electrical component means includes at least one integrated circuit.

29. The device of claim 22 wherein said mechanism is a motor.

30. The device of claim 22 wherein said mechanism is a relay.

31. The device of claim 22 wherein said mechanism is an electronic controller.

32. The device of claim 22 wherein said mechanism is part of a bus network including other electronically activated mechanisms coupled by a single control wire and being activated in response to a particular address signal carried by said wire from a central computer.

33. The device of claim 32 wherein said mechanisms, bus network, and central computer are part of an electrical system of a vehicle.

34. An addressable interface insert device, being removably insertable within an exterior surface area of a casing of a mechanism having a plurality of pins which mate with sockets in a female connector, said mechanism being part of a bus network including other electronically activated mechanisms coupled by a common control wire each being activated in response to a particular address signal carried by said wire from a central computer, said device comprising:

a substrate having holes therein aligned with said pins of said mechanism, said substrate being insertable over said pins such that said pins extend through the holes, said substrate having a perimeter being substantially located within a perimeter of said casing, said substrate being sufficiently thin so as to fit between said mechanism and said female connector while permitting mating engagement therebetween, said substrate being formed from a material selected from a group of dielectric substrates and semiconductor materials;

a contact means for contacting at least one of said pins when said pins extend through the holes in said substrate;

electrical component means on said substrate for providing address decoding of the address signal carried by at least one of said pins in order to selectively activate said mechanism in response to a predetermined address being sent on the wire from the computer; and

an electrical conductor pattern formed on at least one major surface of said substrate, for coupling said contact means to said electrical component means, whereby said interface device decodes the address signal carried by at least one of said pins when inserted onto said pins and said pins are mated with said female connector.

35. A method of performing a preselected function on at least one electrical signal flowing between at least one of a plurality of pins of a relay which mates with sockets in a female relay connector, said method comprising the steps of:

providing a substrate having a series of holes therein corresponding to said pins of said relay;

affixing an electrical component to said substrate for performing the preselected function on the signal;

providing a conductive path on said substrate between the holes and said electrical component;

inserting said substrate onto said relay such that said pins extend through the corresponding holes in said substrate and make electrical connection with said electrical component through said conductive path; and

mating said relay and said female relay connector together, with said substrate disposed therebetween.

36. The method of claim 35 wherein said preselected function provides a timing function for said relay.

37. The method of claim 35 further comprising the step of connecting a ground plate to said substrate in a manner substantially coextensive with said substrate for contacting a ground pin of said relay and said electrical component means.

38. The method of claim 37 wherein said preselected function provides suppression of selected voltages carried by at least one of said pins.

39. A method of selectively activating an electronically activated mechanism having a plurality of pins which mate with sockets in a female connector, said mechanism is part of a bus network including other electronically activated mechanisms coupled by a single control wire and each are activated in response to a particular address signal carried by said wire from a central computer, said method comprising the steps of:

providing a substrate having a series of holes therein corresponding to said pins of said mechanism;

affixing an electrical component to said substrate for decoding the address signal;

providing a conductive path on said substrate between the holes and said electrical component;

inserting said substrate onto said pins such that said pins extend through the corresponding holes in said substrate and make electrical connection with said electrical component through said conductive path; and

mating said pins and said female connector together, with said substrate disposed therebetween.

40. An electrical system for a vehicle, said system comprising:

a plurality of electronically activated mechanisms which actuate various components of said vehicle;

controller means for sending address signals along a control wire bus network to said plurality of mechanisms; and

a plurality of addressable interface insert devices, each of said devices making sliding removable electrical connection between one of said mechanisms and said control wire for decoding said address signals in order to selectively activate its associated mechanism in response to a predetermined address being sent over the bus.

41. The system of claim 40 wherein the bus consists of a single wire.