Connecting power leads to circuit board

An assembler receives a circuit board. The circuit board includes at least a first node and a second node that are adjacent but electrically isolated from each other. There is a gap between the first node and the second node. The first node is electrically isolated from other components on the circuit board. The second node is electrically coupled to circuitry residing on the circuit board. The assembler initiates positioning of a conductive lead of a battery in a vicinity of the first node. The gap between the first node and second node initially prevents the live conductive lead from being in electrical contact with the second node. Eventually, the assembler bridges the gap to provide an electrical connection between at least the conductive lead and the second node to electrically couple the conductive lead to the second node and thus the circuitry residing on the circuit board.

BACKGROUND

Conventional circuit board assembly processes do not lend themselves to connecting one or more live voltage sources to corresponding nodes on a circuit board. For example, each of multiple live battery leads can be aligned and/or made to loosely contact respective nodes on a circuit board. Subsequent to aligning and/or loosely contacting the one or more battery leads to respective nodes on the circuit board, the battery leads can be soldered to respective nodes to provide a more permanent connection.

One issue associated with the technique of soldering live battery leads to a circuit board is the intermittent (e.g., rapid make and break) connectivity between the battery leads and the nodes on the circuit board. For example, the simultaneous and intermittent connections (e.g., via rapid make and break contacts) between the live battery leads and the different nodes can cause a rapid fluctuation and variation of the magnitudes of voltages applied to the different nodes, resulting in damage to corresponding circuit board components.

BRIEF DESCRIPTION OF EMBODIMENTS

Embodiments herein provide one or more unique ways of providing connectivity between one or more conductive leads and corresponding one or more nodes on a circuit board.

For example, in one embodiment, an assembler receives a circuit board. The circuit board includes at least a first node and a second node that are adjacent but electrically isolated from each other. There is an isolation gap between the first node and the second node. The first node can be electrically isolated from other components on the circuit board. The second node is electrically coupled to circuitry residing on the circuit board.

The assembler initiates contact between a conductive lead of a battery to the first and/or second node on the circuit board. The gap between the first node and the second node initially prevents the conductive lead from being in electrical contact with the second node or other circuitry on the circuit board during assembly. Subsequent to initiating the contact between the conductive lead and the first node, the assembler produces an electrical connection (e.g., low impedance path such as one formed via metallic material) between at least the conductive lead and the second node to electrically couple the conductive lead to the circuitry residing on the circuit board.

By way of a non-limiting example, the assembler applies a suitable material such as a mass of solder to a combination of the first node, the second node, and the conductive lead to electrically connect a combination of the conductive lead and the first node to the second node. The solder and/or any portion of the combination can be heated to facilitate a flow of the solder. In such an embodiment, the heated solder flows across the first node, the second node, and the conductive lead to provide a highly, electrically conductive path (e.g., a low impedance path) between the axial end of the conductive lead, the first node, and the second node.

In accordance with further embodiments, the first node can be a metalized through-hole element disposed on the circuit board. The second node can be and/or include a metallic surface pad. Contacting the conductive lead to the first node can include insertion of an axial end of the conductive lead or any portion of the lead thereof through the through-hole. As mentioned, prior to providing the solder and creating the electrical connection, the gap between the first node and the second node electrically isolates the first node from the second node. Subsequent to applying solder, the solder bridges the gap such that the conductive lead, the first node, and the second node become electrically coupled to each other.

In accordance with an alternative embodiment, note that both the first node and the second node can be metal surface pads. An axial end of the conductive lead contacts the first node. As mentioned, prior to providing the solder, a gap between the first node and the second node electrically isolates the first node from the second node. Subsequent to applying solder, the solder bridges the gap such that the conductive lead and at least the second node become electrically coupled to each other. For example, in one embodiment, the solder produces a connection between the axial end of the conductive lead and the first node; the solder also bridges the gap between the first node and the second node, resulting in coupling of the conductive lead to circuitry disposed on the circuit board. Thus, application of the solder to the first node and/or conductive lead and the second node completes a circuit path and connects the voltage of the conductive lead to the circuitry disposed on the circuit board.

In one embodiment, the conductive lead is coupled to an activated (e.g., “live”) voltage source during and after the step of producing the electrical connection. In other words, a live voltage (ground voltage, a voltage greater than ground, a voltage less than ground, etc.) can be applied to the conductive lead before, during, and after the step of providing the solder connection.

Embodiments herein are advantageous over conventional techniques. For example, as mentioned, the first node and second node are spaced by a void, non-conducting gap. Thus, when a conductive lead (e.g., potentially live and being powered by a voltage) is made to contact the first node, there is no damage to the circuitry on the circuit board due to rapid make and break connections between the battery leads and the nodes on the circuit board. By way of a non-limiting example, only after soldering the combination of the first node, second node, and the conductive lead is the conductive lead electrically coupled to the circuit on the circuit board. This controlled technique of coupling and making a connection between the conductive lead and the circuitry reduces a likelihood of damage to the circuitry on the circuit board.

Note further that the step of providing connectivity amongst the conductive leads and/or nodes is shown by way of non-limiting example only and that any suitable method (e.g., welding, brazing, bonding, etc.) can be used to provide the connection.

The width of the gap between the first node and the second node can be any suitable value. In one embodiment, it is desirable that the gap be sufficiently small such that a flow of solder is able to easily bridge the gap and make a connection. By way of a non-limiting example, the gap between the first node and the second node on the circuit board can be a value such as in the range between 0.001 and 0.050 inches (e.g., one thousandth of an inch to 50 thousandths of an inch), although the gap can be of any suitable value outside this range if sufficient solder is applied to bridge the gap.

In one embodiment, the circuit board includes multiple pairings of first and second nodes as discussed above. For example, each pairing can include a respective first node spaced apart by a gap from a respective second node as discussed above. Multiple conductive leads can be coupled to respective first nodes of the pairings. As mentioned, the first nodes are electrically isolated from the circuit components on the circuit board. One or more voltages of the same or different magnitude can be applied to the conductive leads. After making initial contact between the conductive leads and the respective first nodes, an assembler (human or machine) can be configured to produce bridges (e.g., via application of solder) at each of the pairings to connect each of multiple conductive leads to the nodes in the circuit board in an orderly manner. For example, the assembler can be configured to first electrically couple a first conductive lead (such as ground) to circuitry on the circuit board at a first pairing; followed by electrically coupling a second conductive lead (such as 1.5 volts) to the circuitry of the circuit board at a second pairing; followed by electrically coupling a third conductive lead (such as 3.0 volts) to the circuitry on the circuit board; and so on.

These and other more specific embodiments are disclosed in more detail below.

Also, note that this preliminary discussion of embodiments herein purposefully does not specify every embodiment and/or incrementally novel aspect of the present disclosure or claimed invention(s). Instead, this brief description only presents general embodiments and corresponding points of novelty over conventional techniques. For additional details and/or possible perspectives (permutations, elements, aspects, etc.) of the invention(s), the reader is directed to the textual Detailed Description section and corresponding figures of the present disclosure as further discussed below. The following Detailed Description, in addition to providing an intricate description of details of the invention, also provides a further summary of aspects of the invention or inventions.

DETAILED DESCRIPTION

FIG. 1is an example perspective view of positioning a conductive lead with respect to a node on a circuit board according to embodiments herein.

As shown, a surface of circuit board150includes at least a pair of nodes110(e.g., node110-1and node110-2).

In this example, node110-1is a through-hole. Node110-2can be a surface pad of disposed metal. However, note that node110-2can be a metal surface pad as well.

In one embodiment, each of nodes110is made from or includes metal such as copper, tin, metal alloy, etc. Metal or other suitable material can be disposed in the through-hole portion of circuit board150and one or more surfaces of circuit board150as shown.

For example, node110-2can include hole185. Hole185can be coated with metal if desired or be void of material on inner surface of hole185.

Node110-2can be or include a layer of metal disposed on a surface of circuit board150.

In an alternative embodiment, note that nodes such as node110-2(and similar nodes) at periphery of circuit board150may not include or be coated with any metal material.

Initially, as discussed herein, node110-2located at periphery of circuit board150is isolated and not coupled to any traces on the circuit board150.

Conductive path140such as one or more traces on or in a layer of circuit board provide connectivity of the node110-1to circuitry120disposed on the circuit board150.

Pairing of nodes110(e.g., combination of node110-1and110-2) includes a respective gap115. The gap115between node110-1and node110-2ensures that the node110-1and110-2are electrically isolated from each other prior to soldering as will be discussed later in this specification.

By way of a non-limiting example, in one embodiment, the gap115between node110-1and node110-2is in a range between 0.00005 and 0.30 inches, although gap115can be any suitable value. In one embodiment, the gap is chosen as a value between 0.005 and 0.01 inches.

In one embodiment, the gap115is sufficiently small such that hot solder is able to flow and provide connectivity between node110-1and node110-2. In accordance with further embodiments, the gap115can be sufficiently small such that hot solder is able to easily flow and provide connectivity between the tip of conductive lead and node110-2on circuit board150.

Node110-2can include a hole, barrel, etc., through the circuit board150to accept an axial end of conductive lead130. As mentioned, the hole185associated with node110-2through circuit board150may or may not include conduit material such as a layer of metal material on inner walls.

As further described herein, embodiments herein can include a method comprising: disposing a first node110-1and a second node110-2on a circuit board150to be substantially adjacent to each other as shown. Initially, the first node110-1is electrically isolated from the second node110-2. The first node110-1and second node110-2are substantially close in proximity to each other to facilitate a connection (e.g., a solder connection) between the first node110-1and the second node110-2.

FIG. 2is an example perspective view of inserting an axial end of conductive lead130(e.g., a wire, tab, metal tape, etc.) through hole185of node110-2on the circuit board150according to embodiments herein.

FIG. 3is an example top view diagram of circuit board150and protrusion of axial end of the conductive lead130through the hole of node110-2prior to producing a solder bridge between node110-1and node110-2according to embodiments herein.

As mentioned, gap115between nodes110-1and110-2initially provides electrical isolation between node110-1and node110-2. The conductive lead130can be coupled to a live battery node. Insertion of the conductive lead130into hole185of node110-2is safe because the node110-1and node110-2are initially isolated form each other.

FIG. 4is an example top view diagram of nodes110on circuit board150after application of solder to a combination of node110-1, node110-2, and axial end of conductive lead130according to embodiments herein.

The inclusion of metal material (e.g., a metal surface pad) at or in a vicinity of node110-2can be used to facilitate a flow of solder from the tip of conductive lead130and the node110-2. As previously discussed, node110-2may not include metal but merely be a hole185to accept the end of conductive lead130.

Embodiments herein can include providing a solder connection between the tip of conductive lead130protruding through the hole of the circuit board to the node110-1. As mentioned, gap115(such as a lack or void of metal material) provides electrical isolation of the tip of conductive lead130and the node110-1.

Conductive lead130can be coupled to a respective voltage source (e.g., ground, 3 volts, 5 volts, etc.) during a process of applying the solder. In other words, a live voltage can be applied to the conductive lead130when the axial end of lead130is inserted through the node110-1. During such insertion, the gap electrically isolates the voltage of the conductive lead130from being intermittently applied to the circuit120, preventing damage to circuit component120.

Subsequent to heating and applying mass of solder320to the combination of node110-1, node110-2, and the conductive lead130(to which the live voltage is potentially applied) becomes electrically coupled to the circuit120via a path including the conductive lead130, nodes110, the mass of solder320, and the conductive path140.

FIG. 5is an example perspective view diagram illustrating contact of a conductive lead530to a node510-1on circuit board550according to embodiments herein.

In this example, instead of passing through a hole in node510-1, the axial end or tip region of the conductive lead530is bent around edge of circuit board150to provide an initial connection between the tip of conductive lead530and node510-1. In a manner as previously discussed, a mass of solder can be applied to a combination of the axial end of conductive lead530, node510-1, and node510-2to electrically couple the conductive lead to the conductive path140and thus circuit120.

FIG. 6is an example perspective view diagram illustrating a battery pack640and multiple conductive leads130according to embodiments herein. As shown, the batteries650(e.g., battery650-1, battery650-2, battery650-3, battery650-4, battery650-5, battery650-6, . . . ) can be stacked in parallel and series as shown.

In accordance with one configuration, each of multiple sets of batteries can be connected in parallel. The sets of batteries connected in parallel can be connected in series. The conductive leads130(e.g., conductive lead130-1, conductive lead130-2, conductive lead130-3, etc., made from metal such as copper, tin, etc.) can be electrically coupled different node voltages of battery pack640.

In this non-limiting example embodiment, conductive lead130-1is coupled to the negative terminals of batteries650-1,650-5, and650-6. In this example, assume that the voltage at conductive lead130-1is V1 or ground.

Conductive lead130-2is coupled to the positive terminals of batteries650-1,650-5, and650-6as well as negative terminals of batteries650-2,650-3, and650-4. By way of a non-limiting example, the voltage at conductive lead130-2at voltage V2 can be of magnitude 1.5 volts DC.

Conductive lead130-3is coupled to the positive terminals of batteries650-2,650-3, and650-4, and so on. By way of a non-limiting example, the voltage at conductive lead130-2at voltage V2 can be of magnitude 3.0 volts DC.

FIG. 7is an example top view diagram illustrating connectivity of batteries650in battery pack640according to embodiments herein. As previously discussed, the magnitude of voltage (V2) at node130-2is greater than the voltage (V1) at conductive lead130-1; the magnitude of voltage (V3) at node130-3is greater than the voltage (V2) at conductive lead130-2; the magnitude of voltage (V4 or 4.5 volts DC) at node130-4is greater than the voltage (V3) at conductive lead130-3; and so on.

FIG. 8is an example top view diagram illustrating a circuit board150including multiple pairs of spaced node pairs according to embodiments herein.

As previously discussed, each pair can include a respective gap such that the live voltages at respective tips of conductive leads are initially electrically isolated from components on circuit board150. Node pair810-1includes node110-1and node110-2; node pair810-2includes node111-1and node111-2; node pair810-3includes node112-1and node112-2; and so on.

Circuit board150couples to battery pack640. For example, during assembly, conductive lead130-1is inserted through node110-2; conductive lead130-2is inserted through node111-2; conductive lead130-3is inserted through node112-2; and so on.

As previously discussed, the respective gaps between node pairs on the circuit board150prevents the voltages V1 of conductive lead130-1, V2 of conductive lead130-2, V3 of conductive lead130-3, V4 of conductive lead130-4, . . . from being applied to the circuits120-1and120-2during assembly.

One embodiment herein includes providing solder and connectivity to the pairings in a predetermined order. For example, embodiments herein include applying solder to node pairing810-1to create a connection between node110-1and node110-2, followed by applying solder to node pairing810-2to create a connection between node111-1and node111-2, followed by applying solder to node pairing810-3to create a connection between node112-1and node112-2, and so on such that respective voltages V1, V2, V3, . . . are applied to the circuits120-1in an orderly fashion such as from a lowest magnitude voltage to a highest magnitude voltage.

Gaps115provide isolation between respective nodes in a node pairing810. For example, gap115-1includes a void of metal material isolating nodes in node pairing810-1(e.g., node110-1and node110-2); gap115-2includes a void of metal material isolating nodes in node pairing810-2(e.g., node111-1and node111-2); gap115-3includes a void of metal material isolating nodes in node pairing810-3(e.g., node112-1and node112-2); and so on.

More specifically, by way of a non-limiting example, initially the tips of conductive leads are electrically isolated form components on circuit board150. The assembler first applies material such as solder to a combination of the tip of conductive lead130-1, node110-2, and node110-1to electrically connect the conductive lead130-1(e.g., a voltage such as V1 or ground) to node110-1and circuit120-1. Thereafter, the assembler applies material such as solder to a combination of the tip of conductive lead130-2, node111-2, and node111-1to electrically connect the tip of conductive lead130-2(e.g., a voltage such as V2) to node111-1and circuit120-1. Thereafter, the assembler applies solder to a combination of the tip of conductive lead130-3, node112-2, and node112-1to electrically connect the tip of conductive lead130-3(e.g., a voltage such as V3) to node112-1and circuits120-1and120-2, and so on.

In accordance with another embodiment, the conductive leads130can be soldered in any suitable order to nodes110to couple batteries to the circuit board150. A magnitude of each voltage at a respective conductive lead can be any suitable value.

Thus, embodiments herein can include: receiving a circuit board including pairings810of nodes. Each of the pairings includes a primary node (e.g., each of nodes110-2,111-2,112-2, etc., is a primary node) and a secondary node (e.g., each of nodes110-1,111-1,112-1, etc., is a secondary node). Each respective primary node in a pair can be disposed adjacent to a respective secondary node in the pair. The respective primary node is electrically isolated from the respective secondary node in the pair.

For each respective pair of the pairings, embodiments herein can include positioning a respective conductive lead of a power source in a vicinity of a corresponding primary node in the respective pair. More specifically, conductive lead130-1is disposed in a vicinity of node110-2; conductive lead130-2is disposed in a vicinity of node111-2; conductive lead130-3is disposed in a vicinity of node112-2; etc.

Embodiments herein can further include: providing electrical connectivity between each of the multiple conductive leads130and the secondary nodes, the electrical connectivity completing a conductive circuit path connecting the multiple conductive leads to circuitry disposed on the circuit board. More specifically, conductive lead130-1is electrically connected to (secondary) node110-1; conductive lead130-2is electrically connected to (secondary) node111-1; conductive lead130-3is electrically connected to (secondary) node112-1; and so on.

Positioning of the respective conductive lead of the power source in a vicinity of the corresponding primary node in the respective pair can include inserting the respective conductive lead through the corresponding primary node, the corresponding primary node being a corresponding hole in the circuit board.

Positioning of the respective conductive lead of the power source in a vicinity of the corresponding primary node also can include contacting the respective conductive lead to the corresponding primary node in the respective pair.

FIG. 9is an example diagram illustrating connectivity of a circuit board to a battery pack according to embodiments herein.

As shown, battery system1110includes a circuit board150coupled to a respective battery pack640. A respective assembler initially slides the conduit leads through the nodes810from below the circuit board150to above the circuit board (e.g., conductive lead130-1is inserted through node810-1, and so on). As mentioned, the nodes810are initially isolated from the components120on circuit board150to prevent damage. The assembler then solders the respective conductive leads130to nodes110in any suitable order as discussed above.

Note that, embodiments herein are well suited for use in grid power supply applications, battery pack backup banks, transport applications (e.g., mobile battery backup applications), etc. However, note again that embodiments herein are suitable for any applications in which circuitry is coupled to one or more batteries.