Patent Publication Number: US-2023163499-A1

Title: A reversible circuit board for single and dual manifold solenoid valve assembly

Description:
TECHNICAL FIELD 
     This invention relates to a printed circuit board assembly for a manifold solenoid valve assembly. 
     BACKGROUND OF THE DISCLOSURE 
     Manifold solenoid valve assemblies are commonly used in an industrial line to selectively direct pneumatic pressure to various pneumatically operated field devices. The manifold assembly is commonly modular and is assembled from a plurality of individual fieldbus modules including I/O modules, a communication module, and valve manifold members. The manifold member includes one or more control valves in a housing mounted onto a manifold block. The control valves often include a spool valve that slides in a cylinder cavity and is operated by pilot pressure that is selectively provided by a solenoid coil and valve assembly when the solenoid coil is actuated. 
     The spool valve may either be actuated to one position (usually actuated) by a single solenoid valve and a spring may return the spool valve to a second position (usually de-actuated). The power to the single solenoid control valve needs to be continuously on to maintain the spool valve in the actuated position. Because of their power requirements, the single solenoid valves are most commonly used when the actuated position is on for a brief amount of time. Another common type of spool valve is controlled by two solenoid valves where the first solenoid actuates the spool valve to a first position and the second solenoid drives the spool valve to a second position. While the addition of the second control valve may add cost, there is an energy savings in that only a pulse of energy is needed to drive the spool valve to each position. In other words, the control valves do not need to be continuously on to maintain the spool in either the actuated or the deactuated position. 
     The manifold assemblies have the capacity to incorporate many manifold blocks and valve stations connected together which operate many remote field devices in a large manufacturing or industrial line. As such, there exist many differently sized manifold banks with one, two, or more solenoid valve stations and thus many differently sized printed circuit board assemblies built for the differently sized manifold banks. In addition, the printed circuit board assemblies besides being appropriately sized also need to control either a single solenoid valve station or a double solenoid valve station. As a consequence, this multitude of differently sized printed circuit board assemblies for both single and double solenoid valve stations creates an inventory problem. 
     Often these printed circuit boards have traces i.e. lines with decremented contacts at each end so that the output electrical contacts are stepped down to connect to a sequential printed circuit board. For example, U.S. Pat. No. 10,006,557 to DeCarolis discloses the general layout of a circuit board for multiple valve stations having electrical connectors and traces on both surfaces of the circuit board that have either single or double decrements for each valve station to accommodate either single or double solenoid valves but not both on the same board. 
     Attempts have been made to produce reversible printed circuit boards in order to simplify the switching between single-type valve and double-type solenoid valves. These previous attempts still had unacceptable complications. The reversibility was accomplished by flipping the entire board end over end to accommodate either single or double solenoids. These flippable boards thus require electrical connectors on both surfaces of the board to connect to the solenoid valve. In addition, a separate intermediate connector needs to be attached to the selected connector on the appropriate surface of the circuit board. These two features add expense and inconvenience, furthermore, these flippable boards are not suitable for use with boards that have pin assemblies permanently mounted on one surface of the printed circuit board. 
     What is desired is to provide an expeditiously constructed and easily usable printed circuit board assembly that can accommodate both single and double solenoid valve banks whereby the inventory needs of printed circuit boards may be greatly reduced. 
     SUMMARY OF THE DISCLOSURE 
     In accordance with one aspect of the invention, a fluid valve manifold has an electrical conduit for receiving a circuit board assembly that actuates a plurality of valve units mounted to the fluid valve manifold. The circuit board assembly has a circuit board commonly referred to as a printed circuit board with electrical connectors thereon. The circuit board assembly is reversibly mountable to a first position or second position in the electrical conduit such that a respective set of first electrical connectors at a first end or a second set of electrical connectors at a second end opposite that of the first end may be in position to receive electrical signals through the respective connectors. The circuit board has a set of conductive valve lines connected to and extending between the respective set of first electrical connectors and the set of second electrical connectors at opposite first and second ends of the circuit board. 
     When the board is in the first position, conductive valve line extends from a respective first electrical connector to a third connector on a first surface of the circuit board operably leading to one voltage side of the valve unit that serves a single solenoid valve unit. A conductive common line that extends from the first electrical connector to the second electrical connector is operably connected to an opposite voltage side of the single solenoid valve unit at the third connector when the circuit board assembly is in the first position. 
     When the board is in the second position, two conductive valve lines extend from respective second electrical connectors to the third connector leading to one voltage side of the valve unit to serve a double solenoid valve unit. The conductive common line is operable connected to an opposite voltage side of the double solenoid valve unit at the third connector when the circuit board assembly is in the second position. Preferably, the third connector is mounted on the first surface of the circuit board at a central longitudinal axis of the circuit board. In one embodiment, a plurality of third connectors are all mounted along the central longitudinal axis of the circuit board and are symmetrically positioned about a central transverse axis along the width of the circuit board. 
     In one embodiment, the set of conductive valve lines includes a set of single solenoid valve lines extending from the first electrical connector and decremented one step to the second electrical connector for each third connector installed on the circuit board. The set of conductive valve lines includes a set of double solenoid valve lines extending from the second electrical connector to the first electrical connector and decremented two steps for each third connector installed on the circuit board. Preferably, the sets of single solenoid valve lines and double solenoid valve lines that connect to the third connectors are both on the first surface of the circuit board. 
     Preferably, the sets of single solenoid valve lines and double solenoid valve lines that do not connect to the third connector are on both surfaces of the circuit board. 
     Preferably, the second electrical connector of the circuit board is constructed to be connectable to a first electrical connector of a sequentially connected circuit board and the first electrical connector of the circuit board is constructed to be connectable to a second electrical connector of a sequentially connected circuit board. A communication circuit line is on one of the surfaces of the circuit board and extends from the first electrical connector to the second electrical connector without any decrementation. 
     In accordance with another aspect of the invention, a circuit board assembly for a fluid valve manifold includes a circuit board assembly with a plurality of connectors on a surface of a circuit board for connection to at least one valve unit mounted to the fluid valve manifold. The circuit board assembly has a plurality of electrically conductive valve lines extending from one end to a second end being reversibly mountable to a first position or second position in with a valve unit such that a respective set of first electrical connectors at a first end or a second set of electrical connectors at a second end opposite that of said first end may be in position to receive electrical signals through said respective connectors. 
     When the circuit board assembly is in the first position, a conductive valve line extends from a respective first electrical connector to a third connector of the circuit board operably connectable to one voltage side of the valve unit to serve a single solenoid valve unit. A conductive common line is also extending to the first electrical connector and second electrical connector connected to said third connector being operably connectable to an opposite voltage side of the valve unit. 
     When said circuit board assembly is in the second position, two conductive valve lines extend from respective second electrical connectors to the third connector connectable to one voltage side of said valve unit to serve a double solenoid valve unit. The conductive valve line connects to an opposite voltage side of the double solenoid valve unit. The set of conductive valve lines includes a set of single solenoid valve lines extending from said first electrical connector and decremented one step for each third connector installed on the circuit board to the second electrical connector. The set of conductive valve lines includes a set of double solenoid valve lines extending from said second electrical connector and decremented two steps for each third connector installed on the circuit board to the first electrical connector. The set of single solenoid valve lines and the set of double solenoid valve lines that connect to the third connector are on the same surface of the circuit board on the third connectors. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference now is made to the accompanying drawings in which: 
         FIG.  1    is a schematic and side elevational view of one embodiment according to the invention illustrating a circuit boards mounted in manifold electrical pathway formed by plurality of valve units and actuator assemblies operably connected together; 
         FIG.  2    is an enlarged perspective view of one printed circuit board assembly shown in  FIG.  1   ; 
         FIG.  3    is an enlarged plan view illustrating the front surface of the circuit board assembly shown in  FIG.  2   ; 
         FIG.  4    is a enlarged plan view of the rear surface of the circuit board assembly shown in  FIG.  2   ; 
         FIG.  5    is a perspective view of an alternative valve manifold incorporating another circuit board assembly as shown in  FIGS.  6  and  7   ; 
         FIG.  6   , is a plan view of a second embodiment of a circuit board assembly for use in the manifold assembly shown in  FIG.  5    illustrating a front surface of the circuit board; and 
         FIG.  7    is a plan view similar of the rear surface of the circuit board assembly shown in  FIG.  6   . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIGS.  1  and  2   , a fluid control system  10  is modular in nature and depending on the application has a varying number of valve manifold blocks  12  interconnected together. Only four manifold blocks  12  with eight valve units  13  are shown for simplicity of the drawings, i.e. each manifold block mounts two valve units. Some of the valve units  13  may be single solenoid operated and some valve units may be double solenoid operated. Double solenoid valve units are also referred to as dual solenoid valves. All blocks  12  are operably connected to a communication module  15 . 
     Preferably, each valve manifold block  12  may accommodate two valve units  13  each being a single or double solenoid variety. It is possible that the manifold block can mount one valve unit  13  of the single solenoid variety and one valve unit  13  of the double solenoid variety. Each valve manifold block  12  has a passage  28  that receives a printed circuit board assembly  30  which will be described in more detail. 
     Referring now to  FIGS.  3  and  4   , the circuit board assembly  30  has a printed circuit board  34  with pin connectors  36 ,  37 ,  38 , and  39  (often called j-pin connectors) mounted on a front surface  24  of the printed circuit board  34 . Each pin connector is symmetrically mounted along the longitudinal central axis  20  of the circuit board  34 . Further the set of pin connectors  36 - 39  are symmetrically positioned about the minor transverse axis  22  of the board  34 . Preferably the j-pin connectors are equally spaced as well as being symmetrically positioned relative to the minor transverse axis  22  to accommodate uniformly spaced and positioned valve units. This symmetry provides that the circuit board assembly  30  can rotate about axis  23  that passes through the thickness of the board  34  and is transverse to both axis  20  and  22  as described in more detail later. 
     Each board  34  has a first edge  40  and second edge  42  with respective connectors in the form of electrical contacts  44  and  46 . These contacts  44  and  46  may be traces printed directly on board  34 . The contacts  44  and  46  are connected together by lines  50  also in the form of traces. As shown in  FIG.  2   , a standard bridge connector  43  electrically connects the aligned contacts  44  and  46  of adjacent boards  30  shown in  FIG.  1    within the connectors  43 . 
     Referring now to  FIGS.  3  and  4   , the contacts  44 ,  46 , and lines  50  may be on both the front surface  24  and rear surface  26  of the board. The contacts  44 ,  46  and lines  50  are generally arranged to accommodate both single and double solenoid valves depending on how the circuit board is installed. As shown in  FIGS.  3   , the trace contacts  44  each have a specific position labeled A 1 , A 2 , A 3  and connect to lines ( 50 ) on the circuit board. The illustrated circuit board  34  shows a capacity of thirty (30) electrical contacts at each edge which indicates the valve manifold using that circuit board is limited to a maximum of thirty single solenoid valves. The electrical connectors are also symmetrically spaced about the longitudinal axis  20 . The circuit boards can be traced with more or less contacts and lines depending on the needed capacity and applications of the end user as long as the connectors are symmetrically spaced about the longitudinal axis  20 . 
     The first four contacts A 1 -A 4  lead to respective first pin socket contacts  56  at respective pin connectors  36 ,  37 ,  38 , and  39 . Each pin socket contact  56  is connectable to the respective solenoid valve unit  13  of the single solenoid variety. Each valve solenoid unit  13  is also respectively connected to contact pin socket  58  which is connected to the common voltage line  60  that leads to an electrical connector Vcomm with a common voltage. The Vcomm connectors are normally connected to a 24 volt supply to power all of the valve units  13  when the circuit is completed. As shown the first four contacts A 1 -A 4  and the respective lines  50  are on the same front surface  24  of printed circuit board  34 . 
     The remainder of the conductive valve lines  50  labeled A 5 -A 30  on both surfaces  24  and  26  extend from one edge  40  to the second edge and may be decremented four steps or positions from edge  40  to edge  42 , i.e. one step for each valve unit of the single solenoid type. For example see trace A 5  that leads to trace B 15  which can then connect to trace A 1  or B 1  in a subsequent circuit board depending on the rotated position of the subsequent board  34 . 
     Other lines  62  at the bottom of the circuit board can provide auxiliary power lines or function as a protective earth line or function as a serial communication line. Line  62  as well as the Vcomm line  60  extends through the circuit board without any decrementation of position. 
     Referring now to  FIGS.  3    describing the second edge  42 , which when the circuit board  34  is rotated  180  degrees about the axis  23  becomes the left edge, each two electrical contacts  46  labeled B 1  and B 2  are connected to the pin connector  39 , electrical contacts labeled B 3  and B 4  are connected to pin connector  38 , electrical contacts labeled B 5  and B 6  are connected to pin connector  37  and electrical contacts labeled B 7  and B 8  are connected to pin connector  36 . The respective contacts B 1 , B 3 , B 5  and B 7  are connected to third pin connectors  56  of each respective connector  36 ,  37 ,  38 , and  39  while contacts B 2 , B 4 , B 6  and B 8  are connected to a third pin connectors  64  of each respective connector  36 ,  37 ,  38 , and  39 . 
     The pin socket contacts  56  and  64  are connected to the respective solenoids of each double solenoid valve unit  13 . Line  62  which now is in the position to carry the common voltage is operably connectable to the opposite voltage side of each solenoid. Each valve solenoid unit  13  is also respectively connected to contact pin socket  66  which is now in the upper left position as shown in the drawings to connect to the line  62  that is in the position to carry the common voltage. 
     The remainder of the conductive valve contacts  46  and lines  50  labeled B 9 -B 30  on both surfaces  24  and  26  extend from the edge  42  to the edge  40  and are decremented eight steps or positions from edge  40  to edge  42 , i.e. two steps for each valve unit of the double solenoid type. For example, see contact B 9  which has its line stepped to A 15  which can then connect to contact B 1  in a subsequent board  34 . The line  60  which functioned as the common voltage line for the single solenoid valves can now function as an auxiliary power lines, function as a protective earth line, or a rapid communication line. 
     The trace lines  50  leading to the connectors A 6 -A 30  and B 10 -B 30  have been omitted to simplify and clarify the drawings. These traces can be stepped and also switched from the from surface  24  to the rear surface  26  and back again as needed. It is also foreseeable that the line  60  or  62  depending on the rotated orientation of the circuit board about axis  23  can also function as a detection line that can be used to determine if the circuit board is a single board or a double board. The layout of the contacts A 5 -A 30  and B 8 -B 30  that do not connect to pin connectors  52 - 55 , the detection line, and single serial communication line are fully described in U.S. Pat. No. 10,006,557 issued on Jun. 26, 2018 to DeCarolis which is hereby incorporated by reference. In addition an appropriate label “single” or “double” is place proximity to the respective edge  40  and  42 . 
     Referring now to  FIGS.  5 - 7   , an alternative embodiment is shown. In this embodiment, the fluid control assembly  100  may have an integrally formed manifold  112  with valve units  113  mounted on top. A communication module  115  may be mounted near one end. A single board  134  shown in  FIGS.  6  and  7    may extend through the entire manifold. The main difference between this embodiment and the previously described embodiment is that instead of edge connectors or edge traces  44  and  46 , the circuit board has pin connectors  144  and  146  at each end that connect to the traces  148 . The pin connectors are mounted on the same surface at the pin J-connectors  136 ,  137 ,  138 , and  139 . The J-pin connector are at a 45° rotated angle but still provide the needed symmetry about both the longitudinal axis  120  and the transverse axis  122 . Extra pin contacts are spares and are there for longer boards with more valve stations. Each board has at each edge a separate pin connector  147  and  149  that can be used to attach to additional valve units  117  connected through other circuit boards. Only two traces  148  are shown extending out of each separate connector  147  and  149 . Up to six traces for each round pin connector can extend between connectors  147  and  146  and between pin connectors  148  and  149 . 
     Each edge may have an “S” or a “D” indication to inform an operator of the proper rotated orientation for attachment to single or double valve units. Other indications such as a single notch  168  or double notch  169  can also be placed at a respective edge  140  and  142  to indicate the single or double valve application. 
     The advantage of either reversible embodiment is that the circuit board can be used for single valve units or double valve units by proper rotation of the circuit board. The manifold can have both single and double valves in any desired order with the proposed rotation of each board in the manifold. Furthermore, these circuit boards can be attached to other circuit boards either via the card edge connector  43  or through pin connectors. In addition, these reversible boards can also be used in conjunction with standard non-reversible commercially available circuit boards of either the single or double valve station variants. 
     Other variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims.