Abstract:
A method of manufacturing a backplane module includes providing a thermally conductive substrate, and applying a predetermined volume of epoxy extending between a first electrical component disposed on the thermally conductive substrate and a second electrical component disposed on the thermally conductive substrate to create an electrical pathway therebetween.

Description:
BACKGROUND 
       [0001]    1. Field 
         [0002]    The disclosed concept pertains generally to backplane modules. The disclosed concept also pertains to methods of manufacturing backplane modules. 
         [0003]    2. Background Information 
         [0004]    Known backplane modules typically employ conductive metallic traces embedded within a thermally conductive substrate to electrically connect components of the backplane module. Such conductive traces are manufactured before being placed (i.e., embedded) in the thermally conductive substrate. Additionally, the conductive traces are typically connected to contact points, such as pins, of the backplane module by methods such as brazing, soldering, welding, riveting, or staking. This requires skilled labor and assembly time. 
         [0005]    Therefore, there is room for improvement in backplane modules. 
         [0006]    There is also room for improvement in methods of manufacturing backplane modules. 
       SUMMARY 
       [0007]    According to one aspect, a method of manufacturing a backplane module includes providing a thermally conductive substrate, and applying a predetermined volume of epoxy extending between a first electrical component disposed on the thermally conductive substrate and a second electrical component disposed on the thermally conductive substrate to create an electrical pathway therebetween. 
         [0008]    According to another aspect, a backplane module includes a thermally conductive substrate, a plurality of electrical components disposed on the thermally conductive substrate, and at least one predetermined volume of epoxy extending between at least a first one of the electrical components and at least a corresponding second one of the electrical components, thereby creating an electrical pathway therebetween. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which: 
           [0010]      FIG. 1  is an exploded isometric view of a portion of a backplane module for an electrical system, in accordance with an embodiment of the disclosed concept; 
           [0011]      FIG. 2  is a simplified isometric view of an array of predetermined volumes of epoxy for the backplane module of  FIG. 1 ; 
           [0012]      FIG. 3  is an isometric view of the array of epoxy of  FIG. 2 , shown as employed on the backplane module; 
           [0013]      FIGS. 4A and 4B  are isometric and side vertical elevation views, respectively, of the backplane module of  FIG. 3 ; and 
           [0014]      FIGS. 5A and 5B  are isometric and side vertical elevation views, respectively, of a circuit breaker panel including the backplane module of  FIGS. 4A and 4B , in accordance with an embodiment of the disclosed concept. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0015]    As employed herein, the term “number” shall mean one or an integer greater than one a plurality). 
         [0016]    As employed herein, the statement that two or more parts are “connected” or “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. 
         [0017]    As employed herein, the statement that two or more parts or components “engage” one another shall mean that the parts touch and/or exert a force against one another either directly or through one or more intermediate parts or components. 
         [0018]    For purposes of illustration, the disclosed concept is described herein in association with subminiature or aircraft circuit breakers. Such circuit breakers can be employed, for example and without limitation, in aircraft alternating current (AC) systems having a typical frequency of about 400 Hz, but can also be used in direct current (DC) systems. It will be appreciated, however, that the disclosed concept is applicable to a wide range of different electrical systems employing various circuit breakers or other suitable electrical apparatus, for a wide range of different applications. 
         [0019]      FIG. 1  shows a portion of a backplane module  2  in accordance with the disclosed concept. The backplane module  2  includes a thermally conductive substrate  10  (e.g., without limitation, a liquid-crystal polymer (LCP), such as CoolPoly® E-series thermally conductive plastic marketed by Cool Polymers, Inc. of North Kingstown, R.I.; a suitable thermally conductive and electrically insulative epoxy). In the example shown, the backplane module  2  further includes a load connector  60 , a number of load pins(two load pins  70 , 72  are indicated), and a cap layer  90 . 
         [0020]    The thermally conductive substrate  10  includes a number of through holes (two through holes  12 , 14  are indicated). Each of the load pins  70 , 72  extends through a corresponding one of the through holes  12 , 14 . 
         [0021]    The thermally conductive substrate  10  further has an elongated aperture  16  and a film (e.g., plastic layer  18 ) overlying the aperture  16 . The plastic layer  18  has an array of grooves (for ease of illustration only one groove  19  is indicated schematically) and a plurality of through holes  20 . Although only one groove  19  is indicated, it will be appreciated that each groove of the array of grooves of the plastic layer  18  aligns with a corresponding groove of the thermally conductive substrate (discussed below) and terminates at a corresponding one of the through holes  20 . Furthermore, the load connector  60  includes a plurality of pins (two pins  62 , 64  are indicated). Each of the pins  62 , 64  extends through a corresponding one of the through holes  20 , as shown for example in  FIG. 3 . 
         [0022]    Referring to  FIGS. 1 and 2 , the thermally conductive substrate  10  further includes an array of grooves (two grooves  22 , 24  are indicated in  FIG. 1 ) and the backplane module  2  ( FIG. 1 ) further includes an array of predetermined volumes of epoxy (two predetermined volumes of epoxy  40 , 42  are indicated) located in the grooves  22 , 24 . The predetermined volumes of epoxy  40 , 42  are best shown in  FIG. 2 . The epoxy is preferably electrically, conductive epoxy, and more preferably is relatively high purity silver conductive epoxy such as, for example and without limitation, Supreme 10HTFS marketed by Master Bond, Inc. of Hackensack, N.J. 
         [0023]    For ease of illustration and in order to adequately view the load connector  60 , a slightly modified version of the thermally conductive substrate  10  is shown in  FIG. 3  as thermally conductive substrate  10 ′. As shown, predetermined volume of epoxy  40  extends from the load pin  70 , into groove  22 , across one of the grooves of the plastic layer  18 , and to the pin  62 . As a result of being electrically conductive, the predetermined volume of epoxy  40  advantageously functions to create an electrical pathway between the pin  62  of the load connector  60  and the load pin  70 . In other words, the pin  62  of the load connector  60  and the load pin  70  are able to be electrically connected without the need for a separate electrical member, thus eliminating the need for manufacturing and assembly of such separate electrical members (e.g., without limitation, wires; embedded electrical conductors; copper traces). The predetermined volume of epoxy  40  also operates to mechanically couple each of the pin  62  and the load pin  70  to the thermally conductive substrate  10 ′. In this manner, labor and assembly time are significantly reduced, as the need for conventional methods such as, for example and without limitation, brazing, soldering, welding, riveting and staking to couple the load connector  60  and the load pin  70  to the thermally conductive substrate  10 ′ has been eliminated. 
         [0024]    Continuing to refer to  FIGS. 2 and 3 , predetermined volume of epoxy  42  is located in groove  24  and extends between the pin  64 , across one of the grooves of the plastic layer  18 , and to the load pin  72 . Predetermined volume of epoxy  42  thus mechanically couples the pin  64  of the load connector  60  and the load pin  72  to the thermally conductive substrate  10 ′ and also simultaneously creates an electrical pathway extending therebetween. As seen in  FIG. 3 , the example predetermined volumes of epoxy  40 , 42 , in accordance with one embodiment of the disclosed concept, are preferably applied to the backplane module  2  by controlled dispensing from an automated dispensing assembly  44  (e.g., without limitation, a computer numerical control machine). Among other advantages, this controlled application of epoxy  40 , 42  reduces assembly time of the backplane module  2 , and avoids wasted or excess material being used. 
         [0025]    During assembly, once the predetermined volumes of epoxy  40 , 42  are applied to the thermally conductive substrate  10 ′, an insulator  50  is applied that overlies the thermally conductive substrate  10 ′ (as partially shown in simplified form in phantom line drawing in  FIG. 3 ). The predetermined volumes of epoxy  40 , 42  are located between the insulator  50  and the thermally conductive substrate  10 ′. 
         [0026]    Next, the cap layer  90  ( FIGS. 1 ,  4 A and  4 B), which overlies the insulator  50 , is provided. The cap layer  90  includes a number of through holes (two through holes  92 , 94  are indicated). Each of the through holes  92 , 94  corresponds to one of the load pins  70 , 72  and one of the through holes  12 , 14  of the thermally conductive substrate  10 . Additionally, the outer perimeter of the cap layer  90  is shaped relatively similar to the outer perimeter of the thermally conductive substrate  10 . Once the backplane module  2  is assembled, the predetermined volumes of epoxy  40 , 42  are cured, preferably at a temperature greater than 250 degrees Fahrenheit, and more preferably at a temperature of about 300 degrees Fahrenheit with preferable cure cycle of about 5-10 minutes. Additionally, although the disclosed concept has been described in association with heating the already-assembled backplane module  2  to cure the predetermined volumes of epoxy  40 , 42 , it is also within the scope of the disclosed concept to cure the predetermined volumes of epoxy  40 , 42  using any known or suitable alternative method such as, for example and without limitation, using ultraviolet light, before the backplane module  2  is fully assembled. It will also be appreciated that any known or suitable number and/or configuration of grooves and/or volumes of epoxy therefor could be employed other than the example embodiment shown and described herein, which has been provided solely for purposes of illustration and economy of disclosure and is not meant to limit the scope of the disclosed concept to only the particular arrangement shown and described herein. 
         [0027]      FIGS. 4A and 4B  show different views of the assembled backplane module  2 . In the example shown, the backplane module  2  also includes a number of line pins (two line pins  80 , 82  are indicated) corresponding to the load pins  70 , 72 . 
         [0028]      FIGS. 5A and 5B  show different views of one non-limiting example of an electrical system (e.g., without limitation, circuit breaker panel  102 ) employing the backplane module  2 . As seen, the example circuit breaker panel  102  includes a number of electrical apparatus (two circuit breakers  170 , 172  are indicated). Circuit breaker  170  engages and is electrically connected to load pin  70  and circuit breaker  172  engages and is electrically connected to load pin  72 . 
         [0029]    While specific embodiments of the disclosed concept have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.