Patent Publication Number: US-11050175-B1

Title: Conductive connector

Description:
RELATED APPLICATIONS 
     This application is a Continuation of U.S. patent application Ser. No. 16/357,702 filed Mar. 19, 2019, titled “Conductive Connector,” which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/661,547 filed Apr. 23, 2018, titled “Conductive Connector,” both of which are incorporated herein by reference in their entireties for all purposes. 
    
    
     BACKGROUND 
     Often, it may be necessary to electrically connect two circuit boards. 
     SUMMARY 
     A method, system, and apparatus for increasing current connectivity of a circuit board. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Various aspects and embodiments of the application will be described with reference to the following example embodiments. It should be appreciated that the figures are not necessarily drawn to scale. 
         FIG. 1  is a simplified illustration of a connector with an air gap, according to an embodiment of the current disclosure; 
         FIGS. 2 a  and 2 b    are alternative views of a simplified illustration of a female portion of a connector with petals, according to embodiments of the current disclosure; 
         FIG. 3 a    is a simplified illustration of fasteners, a connector, and two circuit boards, according to an embodiment of the current disclosure; 
         FIG. 3 b    is an illustration of a cut away of  FIG. 3 a    with a second fastener screwed into a connector, according to an embodiment of the current disclosure; 
         FIGS. 4 a , 4 b , and 4 c    are alternative views of a simplified illustration of phalanx head fasteners and a connector connecting two circuit boards, according to an embodiment of the current disclosure; 
         FIG. 4 d    is an illustration of a cut away of  FIGS. 4 a - c    with a second fastener screwed into a connector, according to an embodiment of the current disclosure; 
         FIG. 5 a    is a simplified illustration of fasteners, phalanx type washers, a connector, and two boards, according to an embodiment of the current disclosure; 
         FIG. 5 b    is an illustration of a cut away of  FIG. 5 a    with a second fastener pushed through a washer, screwed into a connector, according to an embodiment of the current disclosure; and 
         FIG. 6  is a simplified illustration of a connector with petals that have been pushed partially open, according to an embodiment of the current disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Typically, connecting two circuit boards when a high current transfer is required by the connection may be challenging. Generally, such a connection requires a conductive connection capable of carrying high current. Conventionally, current connectors may not be sufficient to carry such current. 
     In most embodiments, Applicants have realized that an air gap between a board, such as one with a plated barrel, and a connector may lower surface area able to conduct current between the board and the connector. In many embodiments, an air gap may limit the amount of current that may be transferred between boards because of a limit of the conductive area connecting the board and the connector. In certain embodiments, Applicant has realized it may be beneficial to increase a surface area between a board and a connector. 
     In many embodiments, a cut out portion of a board for a cylindrical connector may be called a barrel. In some embodiments, a barrel cutout of a board may be plated with a conductive material. In most embodiments, if a connector between two boards were able to make conductive contact with a portion of a plated barrel of a connector, the amount of power or current transferred by a connector may be increased. In certain embodiments, plating inside a barrel or a cutout of a board may be called a power plane board. In certain embodiments, enabling a connector to hook into plating in a barrel of a board may increase the amount of current transferred by a connector. 
     In further embodiments, a connector with an expandable cylindrical portion for insertion into a barrel may be able to make contact with the plated barrel of a board through expansion, or forming the cylindrical portion may increase the surface area of the connector in contact with the board. In certain embodiments, a fastener may be used to expand an expandable portion of a connector to force the connector to make contact with plating of a power board. In some embodiments, a fastener may force petals of a connector to be in contact with plating of a board to increase the amount of power able to be transferred. In many embodiments, pieces of a connector may be forced to hook into a plating of a barrel of a board by application of a fastener. In many embodiments, the techniques of the current disclosure may enable 50% or more of a plated barrel of a board to be conductively connected to a connector. In some embodiments, a cylindrical portion may expand like an expandable collet. In other embodiments, a cylindrical portion may expand in a similar manner to flower petals. In further embodiments, a cylindrical portion may be a malleable metal that may, through force, be forced to fill in an air gap. 
     In certain embodiments, a cylindrical portion of a connector may be copper. In some embodiments, a cylindrical portion of a connector may be silver. In certain embodiments, a cylindrical portion of a connector may be nickel. In certain embodiments, a cylindrical portion of a connector may be gold. In certain embodiments, a cylindrical portion of a connector may be silver. In other embodiments, a cylindrical portion of a connector may be nickel plated copper. In certain embodiments, a cylindrical portion of a connector may be gold plated copper. In many embodiments, the connector may be copper. In other embodiments, a connector may be copper coated with gold. In other embodiments, a connector may be copper coated with nickel. In other embodiments, a connector may be copper coated with silver. 
     In many embodiments, the current disclosure may enable connecting two circuit boards in a way that allows one or more of the connections to carry a high current. In certain embodiments, a connector may have a cylindrical portion that is malleable. In many embodiments, a malleable cylindrical portion may be formed using force to lower or eliminate an air gap. In certain embodiments, a screw or fastener attaching a board to a connector may have a phalanx type head or triangular head that may, when fastened, force a malleable cylindrical portion to reduce or remove an air gap as the screw or fastener is attached to the connector. 
     Refer now to the example embodiment of  FIG. 1 . In the example embodiment of  FIG. 1 , connector  110  is a conductive element that is between board  115  and  120 . In the example embodiment, board  115  and board  120  have cylindrical cut outs or barrels, which are coated with a conductive material, to receive cylindrical pieces,  111 ,  112 ,  113 , and  114 , of connector  110 . In this embodiment, between board  115  and cylindrical pieces  111  and  112  of connector  110  there are air gaps, such as air gap  116  and  117 , between the cylindrical pieces,  111  and  112 , and the cylindrical cutouts of board  115 , respectively. In this embodiment, the air gaps do not allow good conductivity between the plated barrel of the board and the connector. Screws  125  and  127  are screwed into the cylindrical cutout of board  115  to attach board  115  to connector  110 . After screws  125  and  127  are attached, air gaps remain between cylindrical pieces of connector  110  and the cylindrical cutout of board  115 . 
     Refer now to the example embodiments of  FIGS. 2 a  and 2 b   , which represent alternative views of a female portion of a connector with petals. The example embodiment of  FIGS. 2 a  and 2 b    illustrate different views of connector  210 . Connector  210  has four cylindrical pieces, such as piece  220 ,  225 , and  230 , sized to be insertable into a circuit board. Each cylindrical piece is composed of four pieces or petals such as piece  215 ,  216 ,  217 , and  218 . Each piece or petal is malleable such that each piece or petal may be bent or formed if a sufficient amount of force is applied to the piece or petal. Upon application of sufficient force, each piece or petal can close an air gap between the connector and the cylindrical piece. Each cylindrical piece of connector  210  is threaded to receive a screw type fastener. In the example embodiment of  FIGS. 2 a  and 2 b   , there is spacing between each cylindrical piece. In other embodiments, each cylindrical piece may be layered similar to a closed flower with overlapping petals that may separate but may overlap when forced open. In further embodiments, each cylindrical piece may be arranged like a collet. In other embodiments, a cylindrical portion may be made of any number of pieces or petals. 
     Refer now to the example embodiments of  FIGS. 3 a  and 3 b   , which illustrate a connector, two boards, and two fasteners. In the example embodiments of  FIGS. 3 a  and 3 b   , example embodiments of a fastener connecting two boards is illustrated. In  FIG. 3 a   , board  305  is fastened by connector  310  to connector  320  by screwing fastener  310  into cylindrical portion  315  of connector  320 . As illustrated in the example embodiment of  FIGS. 2 a  and 2 b   , cylindrical portion  315  of fastener  310  has pieces or petals. In this example embodiment as shown in  FIG. 3 b   , after fastener  310  is screwed into connector  320 , the pieces or petals of cylindrical portion  315  are forced apart to fill a portion of an air gap between connector  320  and board  330  by fastener  310 .  FIG. 3 a    also illustrates a second fastener, fastener  330  and a second board, board  325 . In these example embodiments, a barrel or the portion of the board with a cylindrical cut out is coated with a conductive material. In these embodiments, when the expandable portion of the connecter is pushed outwards it increases the surface area of connector  320  conductively connected to board  305 . 
     Refer now to the example embodiment of  FIGS. 4 a , 4 b , 4 c , and 4 d   , which illustrate different views of a fastener, and two boards, where the connector is enabled to increase the ability to carry current between the boards. The example embodiment of  FIGS. 4 a -4 d    illustrate a fastener with a phalanx shaped head capable of applying force sufficient to a fastener, such as the fastener of  FIG. 3 , to close at least a portion of an air gap between a fastener and a board. Fastener  410 , shown in different views in  FIGS. 4 a -4 d   , has phalanx head  415 . Phalanx head  415 , when inserted into cylindrical portion  420 , causes the pieces or petals of cylindrical portion  420  to separate and/mold into the cylindrical cut out of board  430  to at least partially fill air gap between board  430  and cylindrical portion  420 . Fastener  435  illustrates an example embodiment, in different views, of fastener  435  attached to connector  425  to board  430  that has forced the pieces or petals of cylindrical piece of connector  425  open to make contact with board  430 . Also illustrated in  FIGS. 4 a -4 d    is second board  440  and fasteners  445  and  450  attached to connector  425  to hold board  440  to connector  425 . In the example embodiment of  FIGS. 4 a -4 d   , the cylindrical cutout of each board is plated with a conductive material and removing an air gap increases the surface area of connector with the boards. 
     Refer now to the example embodiments of  FIGS. 5 a  and 5 b   , which illustrates an alternative embodiment of a fastener system able to apply force to a cylindrical portion of a connector to increase a surface area of the connecter in contact with a board. In the example embodiment of  FIG. 5 a   , fastener  510  is a screw type fastener. Washer  520  is a phalanx shaped washer. Washer  520  is placed between fastener  510  and cylindrical portion  525  of connector  530  to connect board  535  to connector  530 . As fastener  510  is fastened, or screwed, into cylindrical portion  525 , fastener  510  comes in contact with washer  520 , such as shown in  FIG. 5 b   . As fastener  510  is continued to be fastened or screwed, washer  520  separates or forces pieces of cylindrical connector  525  to at least partially fill an air gap between board  535  and cylindrical portion of connector  530 . Fastener  540  has been screwed into connector  530  to fasten board  535  into connector  530 . Fasteners  550  and  555  are also screwed into board  545 . In the example embodiment of  FIGS. 5 a  and 5 b   , the cylindrical cutout of each board is plated with a conductive material and removing an air gap increases the surface area of connector  530  with the boards. 
     Refer now to the example embodiment of  FIG. 6 , which illustrates how pieces or petals of cylindrical portions of a connector may bend. Connector  610  has cylindrical portions  630 ,  635 ,  640 , and  645 . Cylindrical portion  630  has pieces or petals  611 ,  612 ,  613 , and  614 . In the example embodiment of  FIG. 6 , pieces  611 ,  612 ,  613 , and  614  have been pushed outwards through the application of force by a fastener, such as that of fastener  410  of  FIG. 4 . Also, contrast the position of pieces  611 ,  612 ,  613 , and  614  of  FIG. 6  to the positions of pieces  215 ,  216 ,  217 , and  218  of  FIG. 2 . 
     Referring back to  FIG. 6 , cylindrical portion  645  has visible petals  621 ,  622 , and  623 . In this example embodiment, cylindrical portion  645  has not been pushed outwards and represents a cylindrical portion before bending. Similarly, cylindrical portion  640  has visible portions  619  and  620 . As with cylindrical portion  645 , cylindrical portion  640  has not been pushed out. Cylindrical portion  635  has pieces  615 ,  616 ,  617 , and  618  that have pushed out through the use of force. 
     Having thus described several aspects and embodiments of the technology of this application, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those of ordinary skill in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the technology described in the application. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described. In addition, any combination of two or more features, systems, articles, materials, and/or methods described herein, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure. 
     Also, as described, some aspects may be embodied as one or more methods. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. 
     The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. 
     As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. The terms “approximately” and “about” may be used to mean within ±20% of a target value in some embodiments, within ±10% of a target value in some embodiments, within ±5% of a target value in some embodiments, and yet within ±2% of a target value in some embodiments. The terms “approximately” and “about” may include the target value. 
     In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. The transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively. 
     The terms “approximately” and “about” may be used to mean within ±20% of a target value in some embodiments, within ±10% of a target value in some embodiments, within ±5% of a target value in some embodiments, or within ±2% of a target value in some embodiments. The terms “approximately” and “about” may include the target value.