Abstract:
A system for directly connecting multiple printed circuit boards (PCB) circuits without the need for peripheral connectors. Multiple PCBs are electrically and mechanically interfaced with one or more plated holes or tabs on at least one first PCB and one or more plated tabs or holes on at least one second PCB. The plated tab(s)/hole(s) from said second PCB mate with the corresponding plated tab(s)/hole(s) from said first PCB to form a mechanical and electrical interconnect.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the priority date of the provisional application entitled PIN-HOLE PRINTED CIRCUIT BOARD DIRECT CONNECTION AND METHOD OF FORMING THE SAME, filed by Jessup, et. al on Jan. 31, 2008, with application Ser. No. 61/025,225, the disclosure of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The invention relates generally to printed circuit boards (PCBs), and more particularly to electrically and mechanically interfacing multiple PCBs. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a first printed circuit board having plated holes. 
       FIG. 2  is a perspective view of a second printed circuit board having plated tabs. 
       FIG. 3  is an upper perspective view of the printed circuit board of  FIG. 1  mating with the printed circuit board of  FIG. 2 . 
       FIG. 4  is a lower perspective view of the printed circuit board of  FIG. 1  mating with the printed circuit board of  FIG. 2 . 
       FIG. 5  is a perspective view of a third printed circuit board having plated holes with multiple electrical traces. 
       FIG. 6  is a perspective view of a fourth printed circuit board having plated tabs with multiple electrical traces. 
       FIG. 7  is a perspective view of a fourth printed circuit board having snap action plated tabs. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims. 
   In the following description and in the figures, like elements are identified with like reference numerals. The use of “e.g.,” “etc,” and “or” indicates non-exclusive alternatives without limitation unless otherwise noted. The use of “including” means “including, but not limited to,” unless otherwise noted. A “tab” is a protrusion of the PCB material. A “hole” is defined by an amount of PCB material that has been removed from the PCB by means of drilling, cutting, routering, or by other PCB material removal methods or is otherwise formed through the PCB material. “Plating” refers to the deposition and/or attachment of a metallic conductor (electrically conductive material), such as copper, to circuit board base material. A “plated tab” or “plated hole” is respectively a tab or hole that has undergone a plating process where electrically conductive material (metallic conductor) has been deposited on or attached to the PCB material at or around at least a portion of said tab or hole. 
   Holes are preferably defined in and extending through the printed circuit board, having a first end opening and a second end opening. A hole can be formed various ways, including but not limited to the removal of an amount of PCB material by means of drilling, cutting, and/or routering. Tabs are preferably defined as extensions from a portion of the printed circuit board. A tab can be formed various ways, including but not limited to the removal of an amount of PCB material by means of drilling, cutting, and/or routering. 
   The present invention is a system for connecting printed circuit boards (PCBs) together and the method for manufacturing the same. 
   Referring initially to  FIG. 1 , shown is a first printed circuit board  20  having a first conductive pathway (trace)  52  and a second conductive pathway (trace)  62 . The first conductive pathway  52  electrically connecting a first electrical node  50  of an electrical component (e.g., integrated circuit, capacitor, resistor, switch) to a first hole  54  defined within the first printed circuit board  20 . Shown is also a second conductive pathway  62  electrically connecting a second node  60  of an electrical component to a second hole  64  defined within the first printed circuit board  20 . 
   Optionally, one or more orifices ( 76 ,  86 ,  116 ,  126 ) may be provided through a tab, such an orifice could be filled with solder during the soldering process, providing additional strength to the connection. 
   While  FIG. 1  shows two traces, nodes and holes, it is envisioned that the number of such structures may be one or more. 
   Referring now to  FIG. 2 , shown is a second printed circuit board  30  having a third conductive pathway (trace)  72  and a fourth conductive pathway (trace)  82 . The first conductive pathway  72  electrically connecting a third node  70  of an electrical component (e.g., integrated circuit) to a first tab (pin)  74  extending from the second printed circuit board  30 . Shown is also a fourth conductive pathway  82  electrically connecting a fourth node  80  of an electrical component (e.g., integrated circuit) to a second tab (pin)  84  extending from the second printed circuit board  30 . 
   Referring now to  FIG. 3 , the two circuit boards ( 20 ,  30 ) are shown electrically connected together, by the first tab  74  of the second printed circuit board  30  being inserted into the first hole  54  of the first printed circuit board  20 , and the second tab  84  of the second printed circuit board  30  being inserted into the second hole  64  of the first printed circuit board  20 . Either the first or second printed circuit board contains a feature to maintain spacing between the two boards.  FIG. 4  shows a lower perspective view whereby the distal ends of the tabs  74 ,  84  can be seen extending out of the holes  54 ,  64 , as is preferred. 
   While this embodiment shows a first printed circuit board with pair of holes and a second printed circuit board with a pair of tabs, other configurations are possible, including but not limited to one or more tabs and/or holes on each printed circuit board. 
   This connection (shown in  FIGS. 3 and 4 ) between the first printed circuit board  20  and the second printed circuit board  30  serves as an electrical path between the first and second printed circuit boards, electrically connecting the first node  50  to the fourth node  80  and the second node  60  to the third node  70 . 
   As shown in  FIG. 4 , once mated, electrical signals are routed through the connection between a plated hole and a plated tab. The mated tabs and hole can then be soldered to improve the electrical conductivity of the interconnection of said first printed circuit board and said second printed circuit board. Said soldered interconnection also improves structural rigidity of the mated first printed circuit board and second printed circuit board. 
   While a soldered connection is preferred, in other embodiments, the tab may be shaped in such a way that mechanical coupling or snap action occurs. For instance, the embodiment of  FIG. 7  showing a first node  130 , a second node  140 , a first trace  132 , a second trace  142 , a first tab  134 , a second tab  144 , a first locking means (mechanical coupler)  136  and a second locking means (mechanical coupler)  146 . These tabs configured for snapping into mating holes, such as those shown in the printed circuit board  20  of  FIG. 1 . 
   In the embodiment shown in  FIG. 4 , the first and second printed circuit boards are orthogonally oriented relative to one another, however non-orthogonal orientations are also possible. 
   A “tab” is a protrusion of the PCB material. A tab can be formed in the PCB material by drilling, cutting, routering, or other forms of fabrication such that surrounding PCB material is removed leaving an exposed region. 
   A “hole” is an amount of PCB material that has been removed from the PCB by means of drilling, cutting, routering, or by other PCB material removal methods. It is preferred that the hole extend through the PCB. 
   The term “plating” referring to the deposition and/or attachment of a metallic conductor (electrically conductive material), such as copper, to circuit board base material. A “plated tab” or “plated hole” is respectively a tab or hole that has undergone a plating process where electrically conductive material (metallic conductor, such as copper) has been deposited on or attached to the PCB material at or around at least a portion of said tab or hole. Preferably, a plated tab is composed of electrically conductive material on the bottom, top, and end. Preferably, a plated hole is entirely plated on all sides. It is further preferred that a mated plated tab and plated hole be configured for frictionally fitting together so that the tab releasably connects with said hole. 
   Referring now to  FIGS. 5 and 6 , it is also possible for a tab or hole to contain multiple (two or more) electrical traces. For instance,  FIG. 5  shows a printed circuit board  22  having a first node  90 , a second node  190 , a third node  100 , and a fourth node  200 . The first node  90  having a conductive pathway (trace)  92 , the second node  190  having a conductive pathway (trace)  192 , the third node  100  having a conductive pathway (trace)  102 , and the fourth node  200  having a conductive pathway (trace)  202 . The first and second nodes connected to a shared (but not electrically connected) first hole  94 , whereas the third and fourth nodes are connected to a shared (but not electrically connected) second hole  104 . The first hole  94  defining a first plated portion  95  connecting with the conductive pathway  92  and a second plated portion  195  connecting with the conductive pathway  192 . The second hole  104  defining a first plated portion  105  connecting with the conductive pathway  192  and a second plated portion  205  connecting with the conductive pathway  202 . 
     FIG. 6  shows a printed circuit board  32  having a fifth node  110 , a sixth node  210 , a seventh node  120 , and an eighth node  220 . The fifth node  110  having a conductive pathway (trace)  112 , the sixth node  210  having a conductive pathway (trace)  212 , the seventh node  120  having a conductive pathway (trace)  122 , and the eighth node  220  having a conductive pathway (trace)  222 . The fifth and sixth nodes connected to a shared (but not electrically connected) first tab  114 , whereas the seventh and eighth nodes are connected to a shared (but not electrically connected) second tab  124 . The first tab  114  defining a first plated portion  115  connecting with the conductive pathway  112  and a second plated portion  117  connecting with the conductive pathway  212 . The second tab  124  defining a first plated portion  125  connecting with the conductive pathway  122  and a second plated portion  127  connecting with the conductive pathway  222 . 
   When the embodiment of  FIG. 5  and  FIG. 6  are connected together (not shown in the drawings), the first node  90  would be electrically connected to the fifth node  110 , the second node  190  would be electrically connected with the sixth node  210 , the third node  100  would be electrically connected with the seventh node  120 , and the fourth node  200  would be electrically connected with the eighth node  220 . 
   While the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined herein. 
   Use of the invented method has a number of potential manufacturing benefits, including but not limited to reducing cost by eliminating standard pin or header connectors, providing structural rigidity for the assembly, and providing an electrical connection suitable for signals of high and low speed, high and low current, and high and low voltage. 
   The purpose of the Abstract of the Disclosure is to enable the public, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The Abstract of the Disclosure is neither intended to define the invention of the application, nor is it intended to be limiting as to the scope of the invention in any way. 
   Still other features and advantages of the present invention will become readily apparent to those skilled in this art from this disclosure&#39;s detailed description describing preferred embodiments of the invention, simply by way of illustration of the best mode contemplated by carrying out our invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiments are to be regarded as illustrative in nature, and not as restrictive in nature.