Patent Publication Number: US-9905954-B2

Title: Power transmission device and manufacturing method thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application claims priority of Taiwan Patent Application No. 105105382 filed on Feb. 24, 2016, the entirety of which is incorporated by reference herein. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present disclosure relates to a power transmission device, and in particular to a power transmission device for computer apparatuses. 
     Description of the Related Art 
     In general, computer apparatuses such as network servers need to consume large amounts of power, and power transmission devices are utilized to transmit the power supplied from power supplies to the mother boards of the computer apparatuses. 
     In general, a power transmission device includes many electronic components for power regulation and management. As shown in  FIG. 1 , the electronic components P 30  of the power transmission device P 1  are usually disposed on two circuit boards P 10  and P 20 , which are stacked on each other, in order to properly take advantage of the internal space of the computer apparatus. Moreover, it is convenient for the maintenance of the power transmission device P 1  by deposing the electronic components P 30  on the circuit boards P 10  and P 20  since the current quantity of the power transmission device P 1  is great. 
     In the conventional art, the power transmission device P 1  utilizes the copper pillars P 40  to support the upper circuit board P 20  and separate circuit board P 10  from circuit board P 20 . Moreover, there are two electrical connectors P 50  respectively disposed on the circuit boards P 10  and P 20 . The power transmission device P 1  utilizes a wire P 60  to connect to the electrical connectors P 50 . 
     Although power transmission devices have generally been adequate for their intended purposes, they have not been entirely satisfactory in all respects. Consequently, it is desirable to provide a solution for the problem of how to improve power transmission devices and decrease the cost of manufacturing. 
     BRIEF SUMMARY OF THE INVENTION 
     The present disclosure is to improve the power transmission device, and to decrease the manufacturing cost of the power transmission device. 
     The present disclosure provides a power transmission device, including a first circuit board, a conductive base, a connection element, a second circuit board, and a fixing element. The conductive base is fixed on the first circuit board. The connection element is disposed on the conductive base. The second circuit board is fixed on the connection element. The fixing element is disposed on the second circuit board, and connected to the conductive base by penetrating through the second circuit board and the connection element. The first circuit board is electrically connected to the second circuit board via the conductive base and the connection element. 
     The present disclosure provides a power transmission device, including a first circuit board, a first conductive base, a second circuit board, a second conductive base, a connection element, a first fixing element, and a second fixing element. The first conductive base is fixed on the first circuit board. The second circuit board is located over the first circuit board. The second conductive base is fixed on the second circuit board. 
     The connection element is connected to the first conductive base and the second conductive base. The first fixing element is connected to the first conductive base by penetrating through the connection element. The second fixing element is connected to the second conductive base by penetrating through the connection element. The first circuit board is electrically connected to the second circuit board via the first conductive base, the connection element, and the second conductive base. 
     In some embodiments, the power transmission device further includes a conductive material, and the second circuit board further includes a conductive layer. The conductive material is disposed on the conductive layer, and the connection element is connected to the conductive layer via the conductive material. 
     In some embodiments, the fixing element is conductive, and in direct contact with and electrically connected to the conductive base, the connection element, and the second circuit board. 
     In some embodiments, the power transmission device further includes a first connector and a second connector. The first connector is disposed on the first circuit board, and configured to connect a power supply. The second connector is disposed on the second circuit board, and configured to connect a mother board. 
     The present disclosure provides a manufacturing method of a power transmission device, including fixing a conductive base on a first circuit board; coating a conductive material on a conductive layer of a second circuit board and adjacent to a conductive hole of the second circuit board; disposing a connection element on the conductive material, and fixing the connection element on the second circuit board via the conductive material; putting the connection element on the conductive base; and fixing the second circuit board on the first circuit board by connecting the fixing element to the conductive base, wherein the fixing element penetrates through the second circuit board and the connection element. The first circuit board is electrically connected to the second circuit board via the conductive base and the connection element. 
     In some embodiments, the manufacturing method of the power transmission device further includes fixing a first connector and a first electronic component on the first circuit board; and fixing a second connector and a second electronic component on the second circuit board. 
     In conclusion, the power transmission device of the present disclosure utilizes the conductive base, the connection element, and the fixing element of the electrode structure to electrically connect two circuit boards, and to support the upper circuit board. Therefore, the electrical connectors that electrically connect two circuit boards in the conventional art can be replaced with the electrode structure of the present disclosure. 
     Moreover, the copper pillars in the conventional art can be replaced (or the number of copper pillars reduced) by the electrode structure of the present disclosure. Therefore, the manufacturing cost of the power transmission device is decreased. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein: 
         FIG. 1  is a schematic view of a conventional power transmission device. 
         FIG. 2  is a perspective view of a computer apparatus in accordance with some embodiments of the present disclosure. 
         FIG. 3  is a perspective view of the power transmission device in accordance with a first embodiment of the present disclosure. 
         FIG. 4  is an exploded view of the power transmission device in accordance with a first embodiment of the present disclosure. 
         FIG. 5  is a cross-sectional view of the power transmission device in accordance with a first embodiment of the present disclosure. 
         FIG. 6  is a flow chart of the manufacturing method of the power transmission device in accordance with some embodiments of the present disclosure. 
         FIG. 7  is a schematic view of the manufacturing method of the power transmission device during a middle stage of the manufacturing process in accordance with some embodiments of the present disclosure. 
         FIG. 8  is a perspective view of the power transmission device in accordance with a second embodiment of the present disclosure. 
         FIG. 9  is an exploded view of the power transmission device in accordance with the second embodiment of the present disclosure. 
         FIG. 10  is a cross-sectional view of the power transmission device in accordance with the second embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following disclosure provides many different embodiments, or examples, for implementing different features of the present disclosure. Specific examples of components and arrangements are described below to simplify the present disclosure. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. 
     In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
     The words, such as “first” or “second”, in the specification are for the purpose of clarity of description only, and are not relative to the claims or meant to limit the scope of the claims. In addition, terms such as “first feature” and “second feature” do not indicate the same or different features. 
     The shape, size, and thickness in the drawings may not be drawn to scale or simplified for clarity of discussion; rather, these drawings are merely intended for illustration. 
       FIG. 2  is a perspective view of a computer apparatus A 1  in accordance with some embodiments of the present disclosure. The computer apparatus A 1  is a server, such as a network server. The computer apparatus A 1  includes a casing A 10 , a mother board A 20  main electronic components A 30 , a power supply A 40 , and a power transmission device A 50 . The mother board A 20  is disposed in the casing A 10 . The main electronic components A 30  are disposed on the mother board A 20 . The main electronic components A 30  include a CPU, a display chip, and a memory, for example. 
     The power supply A 40  is configured to supple power to the power transmission device A 50 . The power supply A 40  is configured to convert alternating current to direct current, and transmit the direct current to the power transmission device A 50 . The power transmission device A 50  is connected to the mother board A 20  and the power supply A 40 . 
     The power transmission device A 50  is configured to transmit the power supplied from the power supply A 40  to the mother board A 20 . In some embodiments of the Power over Ethernet (PoE) switch, the power transmission device A 50  is configured to regulate and reducing the voltage of the power and decrease the current quantity of the power supplied by the power supply A 40 , and afterwards to transmit the power to the mother board A 20 . 
     In some embodiments, the power supplied by the power supply A 40  is 12V and 60 A. The power transmission device A 50  converts the voltage of 12V to 5V, and transmits multiple current sets to the mother board A 20  to supply suitable power to the main electronic components A 30 . 
       FIG. 3  is a perspective view of the power transmission device A 50  in accordance with a first embodiment of the present disclosure.  FIG. 4  is an exploded view of the power transmission device A 50  in accordance with a first embodiment of the present disclosure.  FIG. 5  is a cross-sectional view of the power transmission device A 50  in accordance with a first embodiment of the present disclosure. The power transmission device A 50  includes a first circuit board  10 , a second circuit board  20 , two conductive bases  30 , two connection elements  40 , and two fixing elements  50 . 
     The first circuit board  10  is separated from the second circuit board  20 . In this embodiment, the first circuit board  10  is parallel to the second circuit board  20 . The first circuit board  10 , one conductive base  30 , one connection element  40 , one fixing element  50  are arranged in an arrangement direction D 1 . 
     In this embodiment, the power transmission device A 50  further includes a first connector B 10 , first electronic components B 20 , second connectors B 30 , and second electronic components B 40 . The first connector B 10  and the first electronic components B 20  are disposed on the top surface  11  of the first circuit board  10 . In this embodiment, the first connector B 10  and the first electronic components B 20  are directly fixed on and electrically connected to the first circuit board  10 . The first connector B 10  is electrically connected to the first electronic components B 20  via the first circuit board  10 . 
     The first connector B 10  are configured to connect to the power supply A 40  in  FIG. 2 . In other words, the power generated by the power supply A 40  is transmitted to the first circuit board  10  via the first connector B 10 . For example, the first electronic component B 20  is a voltage regulator, an over-current-protection element, a resistor, or a capacitor, for example. 
     In this embodiment, the conductive bases  30 , the connection elements  40  and/or the fixing elements  50  form two electrode structures, wherein one of the two electrode structures is a positive electrode structure, and the other electrode structure is a negative electrode structure. 
     The second circuit board  20  is electrically connected to the first circuit board  10  via the electrode structures (the conductive base  30   s , the connection elements  40  and/or the fixing elements  50 ). In other words, the power supplied by the power supply A 40  is treated by the first electronic components B 20 , and then transmitted to the second circuit board  20  via the electrode structures. 
     In this embodiment, conventional electrical connectors that have a higher cost may be replaced with the electrode structures of the present disclosure to electrically connect the first circuit board  10  and the second circuit board  20 . Therefor, the manufacturing cost of the power transmission device A 50  is decreased. 
     The second connectors B 30  and the second electronic components B 40  are disposed on the top surface  21  of the second circuit board  20 . In this embodiment, the second connectors B 30  and the second electronic components B 40  are directly fixed on and electrically connected to the second circuit board  20 . The second electronic components B 40  are electrically connected to electrode structure via the second circuit board  20 . 
     The conductive base  30  is fixed on the first circuit board  10 . The conductive base  30  is conductive, and made of conductive materials electrically connected to the first circuit board  10 . In this embodiment, the conductive base  30  is a power terminal, and the conductive bases  30  are a positive conductive terminal and a negative conductive terminal. 
     The conductive base  30  includes a conductive body  31  and pins  32 . The conductive body  31  has a top-conductive surface  331  and a retaining hole  332 . In this embodiment, the top-conductive surface  331  is plane, and substantially parallel to the first circuit board  10 . The top-conductive surface  331  is separated from the top surface  11 . The retaining hole  332  is formed on the center of the top-conductive surface  331 . 
     The pins  32  are connected to the conductive body  31 , and the pins  31  and the conductive body  31  are formed as a single piece. The pins  32  are inserted to the inserting holes  12  of the first circuit board  10 , and electrically connected to the first circuit board  10 . The inserting holes  12  are formed on the top surface  11  of the first circuit board  10 . In this embodiment, the pins  32  are welded on the first circuit board  10  to make the conductive base  30  to fix on the top surface  11  of the first circuit board  10 . 
     The connection elements  40  are fixed on the second circuit board  20 , and disposed on the conductive base  30 . The connection element  40  is conductive, and made of conductive materials. The connection elements  40  are electrically connected to the second circuit board  20 . In this embodiment, the connection elements  40  are SMD (surface mounted devices) nuts. 
     The connection element  40  includes a connection body  41  and a protrusion portion  42 . The connection body  41  can be a plate structure, and has a top-connection surface  411  and a bottom-connection surface  412 . The top-connection surface  411  is opposite to the bottom-connection surface  412 . The protrusion portion  42  is disposed on the center of the top-connection surface  411 . The connection body  41  further includes a connection hole  43  penetrating through the center of the connection body  41  and the protrusion portion  42 . 
     In this embodiment, the top-connection surface  411  is substantially parallel to the bottom-connection surface  412 , and the top-connection surface  411  and the bottom-connection surface  412  are flat surfaces. The bottom-connection surface  412  is in contact with the top-conductive surface  331 . Since both of the bottom-connection surface  412  and the top-conductive surface  331  are flat surfaces, the connection element  40  is greatly electrically connected to the conductive base  30 . 
     The top-connection surface  411  of the connection element  40  is in contact with the bottom surface  22  of the second circuit board  20 , and the protrusion portion  42  is located in the conductive hole  23  of the second circuit board  20 . In this embodiment, the bottom surface  22  faces the top surface  11  of the first circuit board  10 . 
     In this embodiment, the second circuit board  20  further includes a conductive layer  24  located on the bottom surface  22  of the second circuit board  20 . In some embodiments, the conductive layer  24  is also located on the side wall of the conductive hole  23  and/or the top surface  21 . 
     In this embodiment, a conductive material M 1  is located between the connection element  40  and the second circuit board  20 . In other words, the conductive material M 1  is disposed between the connection element  40  and the second circuit board  20 . The connection element  40  is connected to the conductive layer  24  via the conductive material M 1 . 
     The fixing element  50  is disposed on the second circuit board  20 , and connected to the conductive base  30  by penetrating through the second circuit board  20  and the connection element  40 . In some embodiments, the fixing element  50  is conductive, and in direct contact with and electrically connected to the conductive base  30 , the connection element  40 , and the second circuit board  20 . In some embodiments, the fixing element  50  is an insulator. 
     In this embodiment, the fixing element  50  is a screw fastened on the conductive base  30 . The fixing element  50  includes a screw head  51  and a screw rob  52 . The screw head  51  is connected to the screw rob  52 , and the screw head  51  and the screw rob  52  are formed as a single piece. The screw head  51  is connected to the top surface  21  of the second circuit board  20 . The screw rob  52  is in the retaining hole  332  by penetrating through the conductive hole  23  and the connection hole  43 . As shown in  FIG. 5 , an end of the screw rob  52  is fastened on the retaining hole  332  of the conductive base  30 . 
     In this embodiment, the conductive base  30  is fixed on the first circuit board  10 , and the connection element  40  is fixed on the second circuit board  20 . Therefore, when the power transmission device A 50  is to be assembling, the connection element  40  is put on the conductive base  30 , first. Afterwards, the fixing element  50  is fastened or fixed on the conductive base  30  after the fixing element  50  penetrates through the second circuit board  20  and the connection element  40  to complete the assembly of the power transmission device A 50 . Therefore, the power transmission device A 50  of the present disclosure can be assembled easily. 
     When the power transmission device A 50  is to be detached, the first circuit board  10  is easily separated from the second circuit board  20  by removing the fixing element  50 . The conductive layer  24  and the conductive material M 1  on the bottom surface  22  of the second circuit board  20  will no be damaged during the power transmission device A 50  is to be assembled or detached. Therefore, the lifespan of the power transmission device A 50  is increased. 
     In this embodiment, since the electrode structure (the conductive base  30 , the connection element  40  and the fixing element  50 ) are made of rigid materials, such as metal, the electrode structure can steadily support the second circuit board  20 , and separate the first circuit board  10  from the second circuit board  20 . Therefore, the copper pillars in conventional art can be replaced or the number of the copper pillars can be reduced by the electrode structure of the present disclosure. The manufacturing cost of the power transmission device is decreased. 
       FIG. 6  is a flow chart of the manufacturing method of the power transmission device A 50  in accordance with some embodiments of the present disclosure.  FIG. 7  is a schematic view of the manufacturing method of the power transmission device A 50  during a middle stage of the manufacturing process in accordance with some embodiments of the present disclosure. 
     It should be understood that additional operations can be provided before, during, and after the method, and some of the operations described can be replaced or eliminated for other embodiments of the method. 
     In the S 101 , the first connector B 10 , the first electronic component B 20 , and the conductive base  30  are fixed on the first circuit board  10 . In the step S 103 , as shown in  FIG. 7 , the conductive material M 1  is coated on the conductive layer  24  of the second circuit board  20  adjacent to the conductive hole  23 . At this time, the conductive material M 1  is cream, molten, or liquid. 
     In this embodiment, the conductive layer  24  is a copper foil layer, and the conductive material M 1  is a solder or conductive paste. By the conductive material M 1  covering the conductive layer  24 , there is no needed to plate precious metals, such as gold or silver to prevent the conductive layer  24  from oxidation. Therefore, the manufacturing cost of the power transmission device A 50  is decreased. 
     In step S 105 , before the conductive material M 1  in cream, molten, or liquid status is solidified, the connection element  40  is disposed on the connection element  40  (as shown in  FIG. 5 ). Since the conductive material M 1  is in cream, molten, or liquid status, the conductive material M 1  is greatly connected to the connection element  40  and the conductive layer  24  of second circuit board  20 . 
     After the conductive material M 1  is solidified, the connection element  40  is fixed on the second circuit board  20  via the solidified conductive material M 1 . In this embodiment, the conductive material M 1  is solidified by standing the second circuit board  20  for a period time, such as 1 minute. 
     Afterwards, the second connector B 30  and the second electronic component B 40  are fixed on the second circuit board  20 . The step of fixing the second connector B 30  and the second electronic component B 40  on the second circuit board  20  can be processed before step S 103 . 
     In step S 107 , the connection element  40  is put on the conductive base  30 . In step S 109 , the fixing element  50  is connected to the conductive base  30  by penetrating through the second circuit board  20  and the connection element  40 . Therefore, the second circuit board  20  is fixed on the first circuit board  10  by the fixing element  50 . 
       FIG. 8  is a perspective view of the power transmission device A 50  in accordance with a second embodiment of the present disclosure.  FIG. 9  is an exploded view of the power transmission device A 50  in accordance with the second embodiment of the present disclosure.  FIG. 10  is a cross-sectional of the power transmission device A 50  in accordance with the second embodiment of the present disclosure. 
     The conductive base  30  includes conductive bases  30   a  and conductive bases  30   b . The conductive bases  30   a  are fixed on the first circuit board  10 . The conductive bases  30   b  are fixed on the second circuit board  20 . The second circuit board  20  is located over the first circuit board  10 . The second circuit board  20  has through holes  25  adjacent to the conductive bases  30   b.    
     The connection element  40  is connected to the conductive base  30   a  and the conductive base  30   b . The first circuit board  10  is electrically connected to the second circuit board  20  via the conductive base  30   a , the connection element  40 , and the conductive base  30   b . In this embodiment, the connection element  40  is a Z-shaped structure. The connection element  40  penetrates through the through hole  25  of the second circuit board  20 , and the conductive base  30   a  is located under the through hole  25 . 
     In this embodiment, the connection element  40  has a first connection portion  44 , a second connection portion  45 , and a central connection portion  46 . The first connection portion  44  is connected to the top-conductive surface  331  of the conductive base  30   a , and the second connection portion  45  is connected to the top-conductive surface  331  of the conductive base  30   b . Moreover, the central connection portion  46  is connected to the first connection portion  44  and the second connection portion  45 . The central connection portion  46  penetrates through the through hole  25 . 
     The fixing elements  50  include the fixing element  50   a  and the fixing element  50   b . The fixing element  50   a  penetrates through the first connection portion  44  of the connection element  40 , and connected to the conductive base  30   a . The fixing element  50   b  penetrates through the second connection portion  45  of the connection element  40 , and connected to the conductive base  30   b.    
     In this embodiment, the fixing element  50   a  is a screw fastened on the conductive base  30   a , and the fixing element  50   b  is a screw fastened on the conductive base  30   b.    
     In this embodiment, the fixing element  50   a  and the fixing element  50   b  are conductive. The fixing element  50   a  is in direct contact with and electrically connected to the conductive base  30   a  and the connection element  40 . The fixing element  50   b  is in direct contact with and electrically connected to the conductive base  30   b  and the connection element  40 . 
     In this embodiment, by changing the lengths of the first connection portion  44 , the second connection portion  45  and/or the central connection portion  46 , the connection element  40  can correspond to various designs of the first circuit boards  10  and the second circuit boards  20 . In other words, the relative position between the conductive base  30   a  and the conductive base  30   b  can adjusted according to the design of the first circuit board  10  and the second circuit board  20 . For example, the conductive base  30   a  may not be located under the through hole  25 . 
     In conclusion, the power transmission device of the present disclosure utilizes the conductive base, the connection element, and the fixing element of the electrode structure to electrically connect two circuit boards, and to support the upper circuit board. Therefore, the electrical connectors that electrically connect two circuit boards in the conventional art can be replaced with the electrode structure of the present disclosure. 
     Moreover, the copper pillars in the conventional art can be replaced (or the number of copper pillars reduced) by the electrode structure of the present disclosure. Therefore, the manufacturing cost of the power transmission device is decreased. 
     The disclosed features may be combined, modified, or replaced in any suitable manner in one or more disclosed embodiments, but are not limited to any particular embodiments. 
     While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.