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A sensor adaptor circuit housing assembly and method of manufacturing includes a circuit board, a housing, an input wire, and a connector. The circuit board includes an electrical circuit configured for receiving a sensor signal and generating a sensor characteristic in response to the received sens

A sensor adaptor circuit housing assembly and method of manufacturing includes a circuit board, a housing, an input wire, and a connector. The circuit board includes an electrical circuit configured for receiving a sensor signal and generating a sensor characteristic in response to the received sensor signal. The housing includes a body and a cavity defined by inner surfaces of the body and adapted for receiving the circuit board, the circuit board being positioned within the cavity. The input wire is configured for receiving the signal from a sensor and can be formed with an insulated solid or stranded conductor. The connector includes a unitary body, a first end of the unitary body attached directly to an end of the input wire, a second end of the unitary body positioned within the cavity and attached directly to the circuit board and making a first electrical connection with the electrical circuit.

대표청구항 ▼

What is claimed is: 1. A sensor adaptor circuit housing assembly comprising: a circuit board having an electrical circuit configured to receive a sensor signal and generate a sensor characteristic in response to the received sensor signal; a housing having a housing body and a cavity defined by inn

What is claimed is: 1. A sensor adaptor circuit housing assembly comprising: a circuit board having an electrical circuit configured to receive a sensor signal and generate a sensor characteristic in response to the received sensor signal; a housing having a housing body and a cavity defined by inner surfaces of the housing body, the circuit board being positioned within the cavity; an input wire configured to receive the sensor signal from a sensor; an input connector having a unitary body, a first end of the unitary body attached directly to an end of the input wire, the end of the input wire and the first end of the unitary body being at least partially encapsulated within a portion of the housing, a second end of the unitary body positioned within the cavity and attached directly to the circuit board and making a first electrical connection with the electrical circuit; and an output connector configured to interface to an external mating connector, the output connector having a unitary body and a first end disposed external to the housing body, the first end of the output connector being configured to attach directly to a mating portion of the external mating connector, the output connector having a second end disposed within the cavity and attached directly to the circuit board, the second end of the output connector making a second electrical connection with the electrical circuit. 2. The assembly of claim 1 wherein the unitary body of the connector includes a sinuous body portion between the first end and the second end of the unitary body to increase the moisture path between the first end and the second end of the unitary body. 3. The assembly of claim 2 wherein the sinuous body portion of the unitary body of the connector comprises a substantially flat metal bar having one or more curves between the first end and second end. 4. The assembly of claim 2 wherein the first end and the sinuous body portion of the unitary body of the connector and the end of the input wire are substantially encapsulated by a portion of the housing body and wherein the second end of the unitary body of the connector is positioned at about a ninety degree angle from the first end of the unitary body of the connector. 5. The assembly of claim 1 wherein the second end of the unitary body of the connector is disposed through a hole defined by the circuit board. 6. The assembly of claim 1 wherein the input wire includes a conductor and an insulated covering, and the first end of the unitary body of the connector includes a compression coupler compressively coupled to the conductor at the end of the input wire. 7. The assembly of claim 6 wherein the input wire includes a stranded conductor. 8. The assembly of claim 1 wherein the end of the input wire and the first end of the unitary body of the connector are substantially encapsulated within a portion of the housing. 9. The assembly of claim 1, further comprising a cavity sealer positioned and dimensioned for closing and substantially sealing the cavity. 10. The assembly of claim 9 wherein the cavity sealer includes at least one of a cover, a potting, a filler, an encapsulant, and a conformal coating. 11. The assembly of claim 9 wherein the cavity sealer includes a potting selected from the group consisting of a resin, an adhesive, silicone, epoxy, and urethane. 12. The assembly of claim 1 wherein the output connector is a solid pin having a substantially right angle bend between the first end and the second end of the output connector. 13. The assembly of claim 12 wherein the second end of the output connector pin is disposed through a hole defined by the circuit board. 14. The assembly of claim 1 wherein the electrical circuit includes a plurality of electrical components mounted to a common side of the circuit board, and a conformal coating covers at least a portion of the electrical components. 15. The assembly of claim 14 wherein the conformal coating is selected from the group consisting of urethane, silicone, and paraxylylene. 16. The assembly of claim 1 wherein the circuit board has edges defining a width and length, the circuit board being dimensioned such that the width and a length are each smaller than the corresponding inner surfaces of the housing body and wherein a potting or an encapsulant is disposed between the edges of the circuit board and the inner surfaces of the housing body. 17. The assembly of claim 1 wherein the housing body includes a plurality of supports within the cavity dimensioned for mounting the circuit board at a predetermined position within the cavity. 18. The assembly of claim 17, where the plurality of supports comprise a plurality of support columns supporting the circuit board at a predefined distance from the inner surfaces of the housing body. 19. The assembly of claim 1, wherein the input wire is a first input wire and the input connector is a first connector, the assembly further comprising a second input wire associated with the sensor and cooperating with the first input wire to receive the sensor signal, and a second input connector having a unitary body, a first end of the unitary body of the second input connector attached directly to an end of the second input wire, a second end of the unitary body of the second input connector positioned within the cavity and attached directly to the circuit board and making a third electrical connection with the electrical circuit. 20. A sensor adaptor circuit housing assembly comprising: a circuit board having an electrical circuit configured to receive sensor signals and generate sensor characteristics in response to the received sensor signals; a housing having a housing body and a cavity defined by inner surfaces of the housing body, the circuit board being positioned within the cavity; a first input wire configured to receive a sensor signal from a first sensor; a second input wire configured to receive a sensor signal from a second sensor; a plurality of input connectors, each input connector of the plurality of input connectors having a first end attached directly to an end of one of the first and second input wires, the ends of the first and second input wires and the first ends of the input connectors being at least partially encapsulated within a portion of the housing, a second end positioned within the cavity, each second end being separately attached directly to the circuit board and making an electrical connection with the electrical; and a plurality of output connectors configured to interface to an external mating connector, each output connector of the plurality of output connectors having a first end disposed external to the housing body, the first ends being configured to attach directly to a mating portion of the external mating connector, each output connector of the plurality of output connectors having a second end disposed within the cavity and separately attached directly to the circuit board and making an electrical connection with the electrical circuit. 21. The assembly of claim 20 wherein each input connector has a unitary body and a sinuous body portion located between the first end and the second end of each input connector, the sinuous body portion including more than one curve, and wherein the second end of each input connector is positioned at about a ninety degree angle from the first end of each input connector. 22. The assembly of claim 20, further comprising a potting material substantially closing and sealing the cavity, the potting material being selected from the group consisting of a resin, an adhesive, silicone, epoxy, and urethane. 23. The assembly of claim 20, wherein the housing body includes a plurality of support columns supporting the circuit board at a predefined distance from the inner surfaces of the housing body.