Patent Publication Number: US-2012039053-A1

Title: System and method for coupling a battery within an embedded system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. Ser. No. 12/246,200 filed on 06 Oct. 2008, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention relates generally to embedded systems and more particularly to systems and a method for coupling a battery within an embedded system. 
     BRIEF DESCRIPTION OF THE INVENTION 
     As the size and complexity of software and computer-related tasks grow, an ability of at least some known computers to handle the requirements associated with the software diminishes. More specifically, known computers are implemented on a printed circuit board and within a housing. Moreover, known computers are assigned a pre-determined volume based on industry standards. As such, space becomes valuable on the printed circuit boards because the volume is constrained. 
     Moreover, other electronic components may also be coupled on the printed circuit board. For example, such electronic components may include a computer processor, a switch, a memory, and/or a power supply However, the more electronic components that are coupled to the printed circuit board, generally, the more likely it is that the printed circuit board may become “space-limited”. Hence, it is difficult to minimize occupancy of an area by the electronic components on the printed circuit board. Moreover, it may be difficult to fit the electronic components within a volume of the housing. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, a method for coupling a battery within an embedded system is described. The method includes creating a hole extending through a printed circuit board (PCB), inserting a portion of the battery into the hole, and electrically coupling the battery to at least one contact. 
     In another aspect, a system for coupling a battery within an embedded system is described. The system includes a battery configured to provide power, and a printed circuit board (PCB) comprising at least one hole extending through the PCB. A portion of the battery is configured to be inserted into the hole. 
     In yet another aspect, an embedded system is described. The embedded system includes a modular housing. The modular housing includes a printed circuit board (PCB) further including a hole extending through the PCB. The embedded system further includes a battery having a portion configured to be inserted into the hole. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side-view of an alternative embodiment of a system for use in coupling a battery within an embedded system. 
         FIG. 2  is a perspective view of the system shown in  FIG. 1 . 
         FIG. 3  is a front view an alternative embodiment of a system of a system for use in coupling a battery within an embedded system. 
         FIG. 4  is a perspective-view of the system shown in  FIG. 3 . 
         FIG. 5  is a front view of a further alternative embodiment of a system for coupling a battery within an embedded system. 
         FIG. 6  is a perspective view of an exemplary battery holder and a contact member used with the system shown in  FIG. 5 . 
         FIG. 7  is a perspective view of yet another alternative embodiment of a system for use in coupling a battery within an embedded system. 
         FIG. 8  is front perspective view of yet another alternative embodiment of a system for use in coupling a battery within an embedded system. 
         FIG. 9  is a rear perspective view of the system shown in  FIG. 8 . 
         FIG. 10  is another perspective view of the system shown in  FIG. 8 . 
         FIG. 11  is a cross-sectional view of the system shown in  FIG. 8 . 
         FIG. 12  is a perspective view of an embodiment of an embedded system. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a side-view of a system  50  for use in coupling a battery  52  within an embedded system (not shown in  FIG. 1 ).  FIG. 2  is a perspective view of system  50 . In the exemplary embodiment, system  50  includes a PCB  28  and a battery  52 . In the exemplary alternative embodiment, battery  52  is a coin cell having a diameter ranging from about 14 millimeters (mm) to about 18 mm. Alternatively, battery  52  is a coin cell having a diameter of more than about 18 mm or less than about 14 mm. Battery  52  has a positive terminal  54  and a negative terminal  56 . 
     In the exemplary embodiment, a hole  58  extends through PCB  28  such that a depth of hole  58  measured along a Z-axis of hole  58  is the same as a thickness  59 , measured along the Z-axis, of PCB  28 . In one embodiment, hole  58  has a cross-sectional area on the X-Y plane ranging from between about 0.19 inch 2  to 0.31 inch 2 . Moreover, in the exemplary embodiment, hole  58  has a length  60 , ranging from about 12.5 mm to about 14.5 mm, and a width  62 , extending substantially parallel to the Y-axis, ranging from about 1 mm to about 3 mm. In another example, hole  58  has a length  60  that is smaller than a diameter of battery  52  and has width  62  that is slightly longer than a thickness of battery  52 . In the exemplary embodiment, a portion  64 , indicated between dotted lines, of battery  52  extends through PCB hole  58  from a top surface  38  of PCB  28  to a bottom surface  66  of PCB  28 . When portion  64  extends through hole  58 , battery  52  is oriented substantially perpendicularly with respect to top surface  38 . In the exemplary embodiment, bottom surface  66  is substantially parallel to top surface  38 . 
     Battery  52  is positioned in a desired location relative to hole  58 . For example, when battery  52  is positioned within hole  58 , battery  52  extends a distance  68  from top surface  38  and a point  70  on a circumference of battery  52 . Additionally, a portion  64  extends a distance  72  from bottom surface  66  and a point  74  on circumference of battery  52 . For example, in one embodiment, of the distance  68  is about 0.54 inches and the distance  72  is between about 0.06 inches and about 0.075 inches. In the exemplary embodiment, when portion  64  extends through hole  58 , battery  52  is originated substantially perpendicularly with respect to top surface  38 . Moreover, when portion  64  is extended through hole  58 , battery  52  is supported within hole  58  such that a likelihood of battery  52  tilting with respect to the Z-axis is facilitated to be reduced. 
     In another embodiment, a user manually inserts battery  52  within hole  58 . For example in another embodiment, hole  58  could be shaped and/or oriented to enable battery  52  to be inserted from any other direction relative to hole  58 . In yet another embodiment, battery  52  is originated obliquely with respect to top surface  38 . Hole  58  may have any cross-sectional shape or size. 
       FIG. 3  is a front-view of an alternative system  100  for use in coupling a battery  52  within an embedded system (not shown in  FIG. 3 ).  FIG. 4  is a perspective view of system  100 . System  100  includes battery  52 , a plurality of contact members  102  and  104 , a plurality of wire traces  106  and  108 , a plurality of contact pads  110  and  112 , and PCB  28 . Contact members  102  and  104  are fabricated from a conductive metal. In the exemplary embodiment, a machine (not shown) is used to fabricate contact members  102  and  104 . When fabricated, wire traces  106  and  108  are embedded within PCB  28 , and contact pads  110  and  112  are embedded within PCB top surface  38 . Contact pad  110  is electrically connected to wire trace  106  and wire trace  106  is electrically coupled to an electrical device  114 , such as a processor or a memory device. Contact pad  112  is electrically coupled to wire trace  108  and wire trace  108  is electrically coupled to electrical device  114 . 
     After battery  52  is inserted within hole  58 , in the exemplary embodiment, adhesive is deposited at specific positions on contact pads  110  and  112 , and contact members  102  and  104  are positioned to contact the adhesive deposited on contact pads  110  and  112 . Moreover, contact member  104  is positioned to contact positive terminal  54 , and contact member  102  is positioned to contact negative terminal  56 . 
     When heated and/or cured, the adhesive facilitates securing contact member  104  to contact pad  110  and contact member  102  to contact pad  112 . An electrical connection is established between electrical device  114  and battery  52  after contact member  104  is secured to contact pad  110  and after contact member  102  is secured to contact pad  112 . Upon establishing the electrical connection, battery  52  may supply power to electrical device  114 . When battery  52  is inserted between contact members  102  and  104 , contact member  102  biases battery  52  against contact member  104  to reduce a chance of battery  52  from tilting with respect to the Z-axis. Similarly, when battery  52  is inserted between contact members  102  and  104 , contact member  104  biases battery  52  against contact member  102 . In an alternative embodiment, contact members  102  and/or  104  are secured with respective contact pads  112  and/or  110  with a mechanical fastener, such as a screw. 
       FIG. 5  is a front-view of an alternative system  150  for use in coupling battery  52  within an embedded system (not shown).  FIG. 6  is a perspective view of an exemplary battery holder  152  and a contact member  154  used with system  150 . System  150  includes battery holder  152 , battery  52 , and contact member  154 . In the exemplary embodiment, battery holder  152  is fabricated from a conductive metal and includes a plurality of prongs  156 ,  158 ,  160 , and  162  that are oriented generally parallel to the Y-axis from a body  164  of battery holder  152 . Battery holder  152  also includes a plurality of flaps  166  and  168  that extend from body  164  in a direction that is generally opposite from prongs  156 ,  158 ,  160 , and  162 , such that a cavity  170  is defined between flaps  166  and  168 . In the exemplary embodiment, a molding machine is used to form battery holder  152 . 
     In the exemplary embodiment, a hole  172  is created within PCB  28 . For example, in the exemplary embodiment, a depth of hole  172 , is the same as thickness  59  of PCB  28 . In the exemplary embodiment, hole  172  has a length  171 , measured substantially parallel to the X-axis, that is longer than a diameter of battery  52 , and a width  173 , measured substantially parallel to the Y-axis, that is wider than a width  62  of battery  52 . 
     Battery holder  152  is inserted in cavity  170  such that prongs  156  and  158  extend above top surface  38  and such that prongs  160  and  162  extend below bottom surface  66 . More specifically, in the exemplary embodiment, prongs  156  and  158  are substantively parallel to top surface  38 , and prongs  160  and  162  are substantively parallel to bottom surface  66 . In the exemplary embodiment, top surface  38  is oriented in the Z-direction, and bottom surface  66  is oriented in a direction opposite to the Z-direction. Moreover, flap  166  is substantially parallel to top surface  38  and flap  168  is substantially parallel to bottom surface  66 . 
     After adhesive is placed on contact pad  112 , in the exemplary embodiment, contact member  154  is positioned against contact pad  112 , and contact member  154  is positioned in contact with battery negative terminal  56 . 
     After battery holder  152  is positioned such that either prong  156  and/or  158  contacts contact pad  110  and such that contact member  154  contacts contact pad  112 , the adhesive is heated/cured to secure prong  156  and/or  158  with contact pad  110  and contact member  154  with contact pad  112 . When contact member  154  is secured to contact pad  112  and battery holder  152  is secured to contact pad  110 , an electrical connection is established between battery  52  and electrical device  114  such that power may be supplied to electrical device  114 . When battery holder  152  is placed with respect to PCB  28 , a portion  176 , shown between dotted lines, of battery  52  extends through PCB hole  172  and a portion  178 , shown between dotted lines, of battery  52  extends through PCB hole  172 . Moreover, when portion  176  extends within hole  172 , a vertical distance  180  between a top surface  182  of flap  166  and top surface  38  ranges from about 0.34 inch to 0.54 inch and a vertical distance  184  between a bottom surface  186  of flap  168  and bottom surface  66  ranges from about 0.06 inch to 0.09 inch. When portion  176  of battery holder  152  extends within hole  172  and a portion of battery  152  is placed within cavity  170 , flap  168  of battery holder  152  supports battery  152  to reduce a chance of battery  52  falling through hole  172 . When portion  176  of battery holder  152  extends within hole  172  and a portion of battery  52  is placed within cavity  170 , contact member  154  applies a force biased towards battery holder  152  to support battery  52  to reduce a chance of battery  52  tilting with respect to the Z-axis. 
     In another embodiment, hole  172  is the same size as hole  58  (shown in  FIG. 2 ). In yet another alternative embodiment, prong  160  and/or  162  contacts bottom surface  66  when the prong  160  and/or  162  is substantially parallel to bottom surface  66 . 
     In yet another embodiment, battery holder  152  does not include at least one of prongs  156 ,  158 ,  160 , and  162 . In another alternative embodiment, battery holder  152  includes more or less than four prongs  156 ,  158 ,  160 , and  162 . In another embodiment, battery holder  152  does not include any of prongs  156 ,  158 ,  160 , and/or  162 , and adhesive is used to secure battery holder body  164  with contact pad  110 . In another alternative embodiment, contact member  154  is the same as either contact member  102  and/or  104  (shown in  FIG. 5 ). 
       FIG. 7  is a perspective view of an exemplary system  200  for use in coupling battery  52  within an embedded system (not shown). System  200  includes a battery cap  202 , battery  52 , PCB  28 , a plurality of contact members  204  and  206 , contact pads  110  and  112 , and a plurality of contact receptacles  208  and  210 . In the exemplary embodiment, hole  58  has a length that is smaller than a diameter of battery  52  and has width that is slightly longer than a thickness of battery  52 . In the exemplary embodiment, contact receptacle  208  includes a hole  212  that extends through contact receptacle  208 , and contact receptacle  210  includes a hole  214  that extends through contact receptacle  210 . For example, in the exemplary embodiment, a depth of hole  212  is the same as a thickness  213  of contact receptacle  208 . As another example, a depth of hole  214  is the same as a thickness  215  of contact receptacle  210 . Contact receptacles  208  and  210  are coupled to top surface  38  via a contact medium, such as solder or a screw. Each contact member  204  and  206  is fabricated from a conductive metal. Moreover, each contact member  204  and  206  may be formed in a way as to act as a spring. Battery cap  202  includes a cavity  216  sized to receive a portion of battery  52 . When fabricated, a portion  218  of contact member  204  extends beyond an internal face  220  of battery cap  202  into cavity  216  and a portion  222  of contact member  206  extends outside an internal face  224  of battery cap  202  into cavity  216 . In the exemplary embodiment, each internal face  220  and  224  opposes cavity  216 . A portion  226  of contact member  204  remains embedded within battery cap  202  and a portion  228  of contact member  206  remains embedded within battery cap  202 . A portion  230  of contact member  204  extends outward battery cap  202  towards PCB top surface  38  and another portion  232  of contact member  206  extends outward battery cap  202  towards top surface  38 . In the exemplary embodiment, each portion  230  and  232  is a contact pin. A molding machine, in the exemplary embodiment, is used to fabricate battery cap  202  and to embed portions  226  and  228  within battery cap  202 . 
     After battery  52  is positioned within hole  58 , battery cap  202  is positioned such that portion  230  is substantially aligned with hole  212  and such that portion  230  extends through hole  212 . Moreover, when battery  52  is positioned within hole  58 , battery cap  202  is positioned such that portion  232  is aligned with hole  214  and contact member portion  232  extends through hole  214 . Portion  230  extends through hole  212  and contacts with wire trace  106  via contact pad  110 . Portion  232  extends through hole  214  and contacts wire trace  108  via contact pad  112 . 
     Moreover, when contact is established between portions  230  and  232  and respective wire traces  106  and  108 , contact is established between contact member  204  and positive terminal  54 , and between contact member  206  and negative terminal  56 . When contact is established between portion  230  and wire trace  106 , between portion  232  and wire trace  108 , between positive terminal  54  and contact member  204 , and between negative terminal  56  and contact member  206 , an electrical connection is established between battery  52  and electrical device  114 . Moreover, when electrical connection is established between battery  52  and electrical device  114 , battery cap  202  supports battery  52  in a generally vertical orientation that is substantially parallel with respect to the Z-axis. 
     In an alternative embodiment, adhesive is dispensed on contact pad  110  and contact pad  112 . Upon placement of battery cap  202 , the adhesive is cured to secure portion  230  to contact pad  110  and portion  232  to contact pad  112 . When portion  230  is secured to contact pad  110  and portion  232  is secured to contact pad  112 , contact member  204  contacts with battery  52 , and contact member  206  contacts battery  52 , an electrical connection is established between battery  52  and electrical device  114  such that power may be supplied to electrical device  114 . 
       FIG. 8  is a front perspective view of an exemplary system  250  for use in coupling battery  52  within an embedded system (not shown).  FIG. 9  is a rear perspective view of system  250  and  FIG. 10  is yet another perspective view of system  250 .  FIG. 11  is a cross-sectional view of an embodiment of system  250 . System  250  includes a battery holder  252 , a contact member  254 , a contact member  256 , battery  52 , and PCB  28 . Battery holder  252  includes a plurality of prongs  258  and  260 , contact member  254  includes a spring contact  262 , and contact member  256  includes a spring contact  264 . Battery holder  252  also includes a plurality of arms  265  and  267  that support battery  52  to facilitate reducing a likelihood of battery  52  tilting with respect to the Z-axis. 
     In the exemplary embodiment, prongs  258  and  260  extend substantially parallel from a main body  268  of battery holder  252 , and battery holder  252  includes a slot  270  that extends through a back surface  272  of battery holder  252 . Battery holder  252  also includes a plurality of side arms  274  and  276  that extend substantially perpendicularly from main body  164 . Battery holder  252  includes a cavity  277  defined between arms  265  and  267 . Contact member  254  is coupled within battery holder  252  at a plurality of contact points  280  and  282 . 
     When contact member  256  is attached to battery holder  252 , a protrusion  288  of contact member  256  extends into cavity  277 . Protrusion  288  may be of any shape or size. More specifically, when contact member  254  is coupled to battery holder  252 , a protrusion  290  of contact member  154  extends into cavity  277  via battery holder slot  270 . 
     Battery holder  252  is fabricated from a nonconductive material. In the exemplary embodiment, a molding machine is used to fabricate battery holder  252 . 
     In an alternative embodiment, battery holder  252  includes a first protrusion (not shown) at contact point  280  and a second protrusion (not shown) at contact point  282 , and contact member  254  includes a first recess (not shown) that is substantially complementary to the first protrusion and contact member  254  includes a second recess (not shown) that is substantially complementary to the second protrusion. In another alternative embodiment, battery holder  252  includes a first protrusion (not shown) at contact point  284  and a second protrusion (not shown) at contact point  286 , and contact member  256  includes a first recess (not shown) that is substantially complementary to the first protrusion and contact member  256  includes a second recess (not shown) that is substantially complementary to the second protrusion. 
     In yet another embodiment, battery holder  252  includes a first recess (not shown) at contact point  280  and a second recess (not shown) at contact point  282 , and contact member  254  includes a first protrusion (not shown) that is substantially complementary to the first recess and contact member  254  includes a second protrusion (not shown) that is substantially complementary to the second recess. In another alternative embodiment, battery holder  252  includes a first recess (not shown) at contact point  284  and a second recess (not shown) at contact point  286 , and contact member  256  includes a third protrusion (not shown) that is substantially complementary to the third recess (not shown) and contact member  256  includes a fourth protrusion (not shown) that is substantially complementary to the fourth recess (not shown). 
     Each contact member  254  and  256  is fabricated from a conductive metal. A stamping machine, in the exemplary embodiment, is used to fabricate contact members  254  and  256 . 
     A plurality of holes  292 ,  294 ,  296 ,  298 , and  300  are formed to extend through PCB  28 . For example, a depth (not shown) of any of holes  294 ,  296 ,  298 , and  300  is the same as thickness  59  of PCB  28 . Hole  292  may be the same as hole  58  (shown in  FIG. 2 ) or hole  172  (shown in  FIG. 6 ). Hole  298  has a length substantially parallel to the X-axis that is longer than a thinnest portion of prong  258 . Moreover, holes  300  and  298  each have dimensions that are substantially complimentary to that of prongs  260  and  258 . Further, holes  294  and  296  have dimensions that are substantially complimentary to that of contact springs  254  and  256 . 
     In the exemplary embodiment, battery  52  is positioned within a portion of battery holder  252  to establish contact between positive terminal  54  and protrusion  288 , and via slot  270 , between protrusion  290  and negative terminal  56 . Moreover, prong  258  is extended through hole  298 , prong  260  is extended through hole  300 , contact spring  254  is extended through hole  294 , and contact spring  256  is extended through hole  296 . When prongs  258  and  260  are extended through holes  298  and  300 , respectively, battery holder  252  is secured with respect to PCB  28  and supports battery  52 . Moreover, when contact springs  254  and  256  are extended through holes  294  and  296 , respectively, contact is established between contact spring  254  and contact pad  110 , and contact is established between contact spring  256  and contact pad  112 , and each respective spring  254  and  256  is then soldered to each respective pad  110  and  112 . Additionally, when contact spring  254  extends through hole  294  and contact spring  256  extends through hole  296 , a distance  293  between contact springs  254  and  256  ranges from about 0.80 inches to about 0.86 inches. 
     Battery holder  252  may have a varying thickness along the Y-axis to accommodate a raised portion of battery  52 . For example, in the exemplary embodiment, a portion  304  of main body  268  is thinner than the remaining portion of main body  268 . In another alternative embodiment, main body  268  of battery holder  252  has approximately the same thickness along the Y-axis. In another alternative embodiment, main body  268  of battery holder  252  has approximately the same thickness along the Y-axis, but may be of any dimension to accommodate battery  52  of various thicknesses. 
     In an alternative embodiment, protrusion  290  includes one or more projections, such as bumps, that face battery  52  and are in contact with battery  52  when protrusion  290  extends through slot  270 . In another embodiment, contact member  256  includes one or more projections, such as bumps, that face battery  52  and that are in contact with battery  52 . In yet another alternative embodiment, contact member  256  does not include protrusion  288  but does include one or more projections that contact battery  52 . In an alternative embodiment, protrusion  290  is divided into two sections with a slit, allowing for dual, independent contact points. 
       FIG. 12  is a perspective view of an exemplary embedded system  400 . In the exemplary embodiment, embedded system  400  includes a plane  402 , such as a midplane or a backplane, and a plurality of modular boards with volumes  404  and  406 . The board in volume  404  includes a PCB  408  and the board in volume  406  includes a PCB  410 . Each volume  404  and  406  may house a single-board computer. PCB  28  (shown in  FIG. 2 ) is an example of any of PCBs  408  and  410 . Any of systems  50 ,  100 ,  150 ,  200 , and/or  250  (shown in  FIGS. 1-5  and  7 - 12 ) are sized to fit within either volume  404  and/or  406 . The cross-sectional area on the xy plane of each PCB  408  and  410  is limited and defined by any of a Compact Peripheral Component Interface (CompactPCI) specification, Versa Module Eurocard (VME), and an Advanced Telecom Computing Architecture (AdvancedTCA) specification. In the exemplary embodiment, both the CompactPCI and AdvancedTCA specifications are provided by PCI Industrial Computer Manufacturers Group (PICMG) and VME specifications are provided by the VITA Standards Organization (VSO). Further, a depth, in the z-direction, of each volume  404  and  406  is controlled by one of CompactPCI, VME, and AdvancedTCA standards. For example, in the exemplary embodiment, vertical distances  68  and  72  (shown in  FIG. 1 ) conform to one of the CompactPCI and AdvancedTCA standards. As another example, vertical distances  180  and  184  (shown in  FIG. 5 ) conform to one of the CompactPCI, VME, and AdvancedTCA standards. In an alternative embodiment, embedded system  400  includes any number of industry standard or custom volumes. 
     In each embodiment illustrated herein, the use of dual contacts facilitates a more reliable connection to the respective battery. Moreover, the use of dual contacts and a recess in the cavity that accepts the battery, helps to keep prevents the battery from being inadvertently installed backwards. More specifically, a recess in the Y-axis is complementary to a raised portion of the battery, helping to prevent the insertion of the battery in the wrong orientation. Furthermore, in each embodiment, one contact is located along the Z-axis, for example, and the second contact is located at a significantly different orientation than the first contact, such that a battery installed incorrectly would not touch one of the two contacts. As a result, each respective battery holder is essentially “Murphy-proofed,”such that the battery will only fit within the holder in one orientation, or at the least, in cases where the battery were forced into the holder, wouldn&#39;t touch both contacts. 
     Technical effects of the herein described methods and systems for coupling battery  52  include providing systems  50 ,  100 ,  150 ,  200 , and  250 , (shown in  FIGS. 1-5  and  7 - 12 ) that comply with one of the CompactPCI, VME, and AdvancedTCA standards. A mounting depth of any battery  52  used with any of systems  50 ,  100 ,  150 ,  200 , and  250  positions the battery such that it conforms to volumes defined in the specifications provided by one of the CompactPCI, VME, or AdvancedTCA standards. Other technical effects include a reduction in occupancy of the cross-sectional area by 67% by any of holes  58 ,  172 , and  292 . The reduction in the cross-sectional area by any of holes  58 ,  172 , and  292  leaves more cross-sectional space on PCB  28  for attaching electrical devices to PCB  28 . 
     Exemplary embodiments of a method and systems for coupling a battery are described above in detail. The systems are not limited to the specific embodiments described herein. For example, the systems may be used in combination with other electrical systems. 
     While various embodiments of the invention have been described, those skilled in the art will recognize that modifications of these various embodiments of the invention can be practiced within the spirit and scope of the claims.