Abstract: A control unit which meets desired packaging requirements, eliminates the need for right-angle or L-shaped pins, and has a reduced footprint. The control unit includes a connector, a circuit board connected to the connector, and an encapsulation housing. The encapsulation housing surrounds at least a portion of the circuit board and at least a portion of the connector. The connector includes a base flange, a shroud integrally formed with the base flange, a plurality of pins extending through the base flange and partially extending into the circuit board. The connector also includes at least one grounding pin connected to the base flange which partially extends into the circuit board. A bushing extends through a mounting post formed as part of the base flange such that the bushing is in contact with the grounding pin, where the grounding pin and the bushing are part of a grounding connection.

Abstract: A thermal management system includes a transmission, a heat exchanger, and a transmission control unit. The transmission includes: a transmission housing; a transmission pan housed within the transmission housing; transmission fluid contained within the transmission pan; and a transmission fluid conduit configured to circulate the transmission fluid between the transmission pan and within the transmission housing. The heat exchanger is disposed within the transmission housing and has a first surface positioned on the transmission pan and a second surface. The transmission control unit is disposed on and supported by the second surface of the heat exchanger such that the heat exchanger controls the temperature of the transmission control unit.

Abstract: A retainer device which connects to a printed circuit board (PCB) to provide added structural rigidity to a capacitor (or other electrical component) mounted to the PCB. The retainer device is able to provide increased durability of capacitor leads against vibrational fatigue. The retainer device is designed to add structural rigidity to single or multiple capacitors soldered to a PCB. The retainer device exerts a positive force against the capacitor, pressing the capacitor against the PCB. This in turn limits the fatigue deflection of the capacitor leads. The retainer device has at least one spring retention ring, where the spring retention ring is able to apply force to the capacitor, which aids in ensuring that the capacitor is flush to the surface of the PCB, which reduces the load on the leads of the capacitor.

Abstract: A motor retainer includes a base and at least one arm. The base has an inner surface and an outer surface and includes a washer having at least one concave wave adjacent to at least one convex wave. The at least one arm extends away from the inner surface of the base and tapers towards a center of the motor retainer.

Abstract: A thermal management system includes a transmission, a heat exchanger, and a transmission control unit. The transmission includes: a transmission housing; a transmission pan housed within the transmission housing; transmission fluid contained within the transmission pan; and a transmission fluid conduit configured to circulate the transmission fluid between the transmission pan and within the transmission housing. The heat exchanger is disposed within the transmission housing and has a first surface positioned on the transmission pan and a second surface. The transmission control unit is disposed on and supported by the second surface of the heat exchanger such that the heat exchanger controls the temperature of the transmission control unit.

Abstract: An electronic controller which includes a cover connected to a base plate, a housing, and a printed circuit board disposed in the housing. The base plate includes a press-fit inspection opening or aperture, and a cover is placed on the base plate over the opening, creating a seal path between the cover and the edge of the opening in the base plate. In one embodiment, there is a sealant, such as room temperature vulcanization (RTV) or heat cured sealant, dispensed on the sheet metal base plate around the perimeter of the opening, and the sealant is cured to prevent the formation of a leak path. Prior to the curing process, the cover is held in place by a pressure sensitive adhesive (PSA), as the sealant is cured. The controller is treated to a curing process to cure the sealant between the cover and the base plate.

Abstract: An electronic control module which has a housing, a cavity formed as part of the housing, and a connector. The control module also includes a plurality of pins, and a portion of the housing is integrally formed around the pins such that a first end of each of the pins are part of the connector, and a second end of each of the pins is located in the cavity. The control module also has a cover with a large portion and a small portion. A sealant is disposed between part of the cover and the housing to provide a seal between the cover and the housing. The small portion of the cover is bendable relative to the large portion to allow an inspection of the pins after the pins are press-fitted into the circuit board as the cover is connected to the housing.

Abstract: A method of creating a sealed, un-mated electrical connector system using single insertion press-fit pins. Using single insertion press-fit pins allows for use of simple plastic parts for the connector shroud and a true position assurance comb in conjunction with single insertion press-fit pins. The result is a lower cost for the final connector assembly. Less plastic is needed for the combined shroud and true position assurance comb, because the true position assurance is provided in part by the shroud, and in part by the position assurance comb.

Abstract: A lead frame assembly which allows for the connection of multiple individual fixed components in various locations, while alleviating tolerance concerns by having a flexible lead frame. The lead frame assembly includes several sub-lead frames, and a plurality of interconnects which connect each of the sub-lead frames together. The lead frame assembly also includes a plurality of segments, and each segment surrounds one of the sub-lead frames, to electrically isolate each sub-lead frame. Various components are electrically connected by incorporating stamped receptacles, or slot terminals, in the sub-lead frames. The interconnects along with plastic voids allow the various attached components to have tolerance flexibility relative to one another, as various components are attached to each of the slot terminals.

Abstract: A lead frame assembly which allows for the connection of multiple individual fixed components in various locations, while alleviating tolerance concerns by having a flexible lead frame. The lead frame assembly includes several sub-lead frames, and a plurality of interconnects which connect each of the sub-lead frames together. The lead frame assembly also includes a plurality of segments, and each segment surrounds one of the sub-lead frames, to electrically isolate each sub-lead frame. Various components are electrically connected by incorporating stamped receptacles, or slot terminals, in the sub-lead frames. The interconnects along with plastic voids allow the various attached components to have tolerance flexibility relative to one another, as various components are attached to each of the slot terminals.

Abstract: A method of creating a sealed, un-mated electrical connector system using single insertion press-fit pins. Using single insertion press-fit pins allows for use of simple plastic parts for the connector shroud and a true position assurance comb in conjunction with single insertion press-fit pins. The result is a lower cost for the final connector assembly. Less plastic is needed for the combined shroud and true position assurance comb, because the true position assurance is provided in part by the shroud, and in part by the position assurance comb.