Controller with helical spring contacts

A controller for use in a vehicle, comprising:

• an electronic device having at least one terminal with a maximum transverse span;
• a circuit board having circuitry for controlling and operating said electronic device, said circuit board having a support surface facing generally towards said electronic device for supporting said circuitry and an opposing surface facing generally away from said electronic device and opposite said support surface, said circuit board defining a spring-receiving opening, and an annular metal contact mounted on at least one of said surfaces about said spring-receiving opening;
• an interconnect for connecting said terminal of said electronic device to said annular metal contact of said circuit board, said interconnect comprising a coiled spring contact having a contact-engaging portion connected to said annular metal contact of said circuit board, said spring having a terminal-engaging portion for contacting said terminal of said electronic device, said spring contact having coils with a maximum inside coil diameter greater than the maximum transverse span of said terminal for slidably receiving and contacting said terminal during operation of the vehicle, and some of said coils in proximity to said terminal-engaging portion having an outside coil diameter less than said spring-receiving opening of said circuit board so that said coils can pass through said spring-receiving opening of said circuit board;
• and
• a housing comprising a spring-receiving chamber, said spring-receiving chamber capable of receiving and engaging said terminal-engaging portion of said coiled spring and, by engaging said terminal-engaging portion, providing a retention feature for said coiled spring when said coiled spring is disposed in said spring-receiving chamber and said terminal is inserted into, and makes electrical connection with, said coiled spring.

A controller for use in a vehicle, comprising:

• an electronic device for regulating operation of a vehicle, said electronic device being selected from the group consisting of a solenoid, integrated circuit , and switch, said electronic device having at least one elongated terminal selected from the group consisting of a pin, post and blade, said terminal having a width or diameter defining a maximum transverse span;
• a printed circuit board having circuitry for activating, controlling and operating said electronic device, said circuit board having a component side providing a support surface facing generally towards said electronic device for supporting said circuitry, an underside providing an opposing cover-engaging surface facing generally away from said electronic device and opposite said support surface, said circuit board defining a spring-receiving opening with a maximum inside opening-diameter, a grommet-like annular metal contact assembly connected to said circuitry, said annular metal contact assembly comprising an annular component side-contact mounted on said support surface about said spring-receiving opening and an annular underside-contact mounted on said opposing surface about said spring-receiving opening, said annular contact assembly having a tubular middle portion extending between and connecting said annular component side-contact and said annular underside-contact, said tubular middle portion of said annular contact assembly defining a contact-opening substantially concentric with said spring-receiving opening, said contact-opening having a maximum inside opening-diameter;
• an interconnect for connecting said terminal of said electronic device to said annular metal contact assembly of said circuit board, said interconnect comprising a coiled tapered metal spring contact comprising generally funnel-shaped spiral coils with a minimum inside coil diameter and an outside coil diameter, said spiral coils cooperating with each other to define an interior terminal-receiving opening positioned radially inwardly of and annularly surrounded by said coils to slidably and reciprocatingly receiving said terminal of said electronic device during operation of the vehicle, said minimum inside coil diameter being greater than the maximum transverse span of said terminal, said coiled tapered metal spring contact having a contact-engaging end portion and a terminal-engaging end portion, said contact-engaging end portion having an enlarged head fixedly connected and soldered to said annular component side-contact on said support surface of said circuit board, said enlarged head having a maximum outside head-diameter larger than said maximum inside opening-diameter of said spring-receiving opening and said contact-opening to prevent said enlarged head of said tapered metal spring contact from passing through said spring-receiving opening and said contact opening, said contact-engaging end portion comprising a spiral foot for slidably engaging and contacting said terminal of said electronic device during operation of the vehicle, said spiral foot having a maximum outside foot-diameter smaller than said maximum outside head-diameter of said enlarged head, said spiral foot being positioned axially opposite said enlarged head at a location spaced from and said underside of said circuit board, said metal spring contact having a tapered spiral body extending between and connecting said enlarged head to said tapered foot, said tapered spiral body having a maximum outside body-diameter less than said maximum inside-opening diameter of said spring-receiving opening and said contact-opening to permit said spiral body of said spring contact to pass through both said spring-receiving opening and said contact-opening of said circuit board;
• and
• a housing assembly comprising an underside housing, said underside housing comprising an impact-resistant cover for protecting and covering at least a portion of the underside of said circuit board, said cover comprising a fluid impervious material for substantially preventing motor oil, transmission fluid and other fluids from an engine of a vehicle from contacting said circuitry on said circuit board, said cover having peripheral edge portions for matingly engaging and being fluidly sealed to the underside of said circuit board about said circuitry, said cover defining a recessed spring-receiving chamber providing a socket for receiving said spiral body and spiral foot of said spring contact, said socket having a minimum socket-diameter larger than said maximum outside foot-diameter of said spring contact, and said cover comprising a round socketwall with a substantially planar bight providing an impact plate for engaging said spiral foot and compressing said spring contact when said cover is matingly engaged to the underside of said circuit board.