Patent Description:
In this invention, the term "layer" refers to an electrically conductive layer of the printed circuit board PCB.

Any printed circuit board PCB has two outer layers, namely the layers that are placed at the exterior of said printed circuit board PCB. For the invention, it is not relevant to individualize each of the two outer layers, because humidity can occur on any of the outer layers, and in particular on any of the outer surfaces of the two outer layers of the printed circuit board PCB.

The term "ground plane" refers exclusively to the layer of copper foil connected to the printed circuit board's ground point, serving as return path for current from many components.

One of the outer layers may be the ground plane.

The term "via", also known as vertical interconnect access, is an electrical connection between layers of the printed circuit board PCB.

There is a wide variety of situations of humidity in a printed circuit board PCB, stemming from the fact that today, printed circuit boards PCBs are used in a wide range of fields of sub-assembly of some embedded system, such as but not limited to: in the automotive industry for various electronic control units of the vehicles; in computers and hand-held devices of all sizes; in camera sensors; in sensors in general, etc..

Humidity can be of various sources, but generally falls within two categories: in gaseous form, namely vapour, and in liquid form, usually water vapour condensation or water from direct sources.

Each printed circuit board PCB may be exposed to different types and levels of humidity, because of factors such as: the location of the printed circuit board PCB in the general architecture of the sub-assembly comprising it, the electrical or electronical components accommodated by the printed circuit board, the ambient temperature and humidity and the speed of their variation with time, the characteristics of the printed circuit board such as the size, the number of layers. For example, in some cases, humidity may affect primarily areas located in one outer surface of the outer layer in one specific zone of the printed circuit board PCB, while in other cases humidity may affect the entire outer surface of the outer layers of the printed circuit board in a diffuse manner.

As a general rule, when humidity from various sources reaches any outer surface of the outer layer or both outer layers of a printed circuit boards PCB, hydrolysis occurs, creating the condition of electrochemical corrosion. Further on, the electrochemical corrosion may be the source of various effects such as short-circuits, overheating of the printed circuit board PCB, partial or total interruption of the functioning of the electrical or electronical components accommodated by said printed circuit boards PCB and, in extreme cases, may lead to explosion.

As a consequence, printed circuit boards PCB need to be protected against excess of humidity. Said protection consist of identification of excess humidity, followed by appropriate measures to protect the printed circuit boards PCB against humidity.

For the purpose of such detection, humidity sensors are used to detect changes in relative humidity or temperature in many components, including printed circuit boards PCB. Said humidity sensors are placed by the manufacturer in predetermined place or places of the printed circuit board PCB.

<CIT> for example disclosed a modular sensor unit for a motor vehicle for detecting ambient conditions which comprises at least two sensor modules, wherein a first sensor module has a rain and/or condensation sensor, and a second sensor module has at least a light and/or solar sensor. In this case, there preferably is an electrical and/or electronic connection between the sensor modules.

<CIT> discloses a humidity sensing module for sensing humidity on at least one pre-determined humidity-prone zone of at least one of the outer surfaces of the two outer layers of a printed circuit board connected to a voltage source. The mentioned printed circuit board comprises at least two electrically conductive layers (a ground plane, a signal layer) ; a plurality of positive and negative vias is arranged in pairs such that the positive via of each pair has an end connected to the pre-determined humidity-prone zone of the outer surface of the two outer layers and the other end connected to a transistor layer, and the negative via of each pair has an end connected to the pre-determined humidity-prone zone of the same outer surface of the two outer layers and the other end connected to the ground plane.

Moreover, <CIT> discloses a resistive rain sensor that uses a patterned electrode as detector configured to determine single drops of rain.

One of the disadvantages in the prior art is the lack of the possibility to detect the humidity in multiple zones of the printed circuit board PCB and/or in specific zones of said printed circuit board PCB.

Yet another disadvantage as it appears from the prior art is that the humidity sensors for printed circuit board PCB are not efficient in operation and/or detection since they provide only local reading, while they need a lot of space to be mounted on the printed circuit board PCB.

The problem solved by the invention is to provide a humidity sensing module able to detect the humidity in multiple zones of any of the outer surfaces of a printed circuit board PCB and to provide a possibility to adjust the sensitivity of the humidity sensing module according to the characteristics of each individual printed circuit board PCB.

In order to solve the problem, the inventors conceived a humidity sensing module for detecting humidity on at least one pre-determined humidity-prone zone of at least one of the outer surfaces of the two outer layers of a printed circuit board, said printed circuit board being connected to a voltage source, and comprising at least two electrically conductive layers: the first of the at least two electrically conductive layers being the ground plane and the other of at least two electrically conductive layer being a signal layer supporting electrical or electronical components.

The humidity sensing module further comprises a transistor layer as a further signal layer, said transistor layer and said ground plane being connected to said voltage source by two resistors configured to work as a voltage divider, such as:.

The humidity sensing module further comprises a plurality of vias, which are arranged in pairs, such that:.

and an external decision taking module connected between said two resistors being configured to read the signal and interpret it depending on the different voltage level between said resistors.

The humidity sensing module according to the invention is configured such that when humidity between a positive via and a negative via, placed at a predetermined distance between them on the same outer surface, exceeds a humidity threshold, they become electrically connected determining a signal of different voltage level between said resistors depending on the level of humidity exceeding a predetermined threshold and thus allowing said signal to be read and interpreted by said external decision taking module.

In another aspect of the invention it is provided a hydrolysis prevention module comprising the humidity sensing module, wherein the external decision taking module is configured to disconnect the current flow in at least one pre-determined humidity-prone zone Zj of at least one of the outer surfaces of the two outer layers of a printed circuit board in order to limit the effect of hydrolysis on at least one pre-determined humidity-prone zone of at least one of the outer surfaces of the two outer layers of a printed circuit board when the level of humidity exceeds a predetermined threshold.

In another aspect of the invention, it is provided a humidity sensor comprising said humidity sensing module or said hydrolysis prevention module.

The main advantages of this invention are the following:.

Further advantages will stem from the description, claims and drawings.

The principle of the invention is based on the inventor's observation that solutions of measuring the humidity in a printed circuit board PCB from the state of the art are configured to measure said humidity in a single zone of it, whereas in practice, the zone or zones most affected by humidity may not necessarily be the ones where the humidity sensors are placed.

The above-mentioned disadvantages of prior art are overcome by providing a humidity sensing module, a humidity sensor, and a hydrolysis prevention module comprising said humidity sensing module capable to detect if an excess of humidity occurs in any zone of the outer surfaces of the outer layers of the printed circuit board PCB.

With reference to <FIG>, in a first aspect of the invention it is disclosed a humidity sensing module for detecting humidity on at least one pre-determined humidity-prone zone Zj of the at least one of the outer surfaces of the two outer layers of a printed circuit board (PCB), the pre-determined humidity-prone zone Zj being the zones where humidity is more likely to occur on any of the two outer surfaces of the two outer layers of the printed circuit board or on both.

For each individual printed circuit board PCB, the localization of the at least one pre-determined humidity-prone zone Zj of any of the outer surfaces of the two outer layers of the printed circuit board PCB may be previously known from the experience or estimated in case there is no experience. The exact localization of at least one pre-determined humidity-prone zone Zj for at least one of the outer surfaces of the two outer layers of the printed circuit board PCB can be made using the dimensions of the printed circuit board PCB, just like in a map.

Further on, in the invention it is defined a humidity threshold that refers, as its name suggests, to a threshold separating the humidity value that is considered not affecting negatively the at least one pre-determined humidity-prone zone Zj from the humidity value considered to be capable of damaging the printed circuit board PCB in the at least one pre-determined humidity-prone zone Zj.

The humidity threshold can be expressed either as relative humidity or as absolute humidity, depending on the particulars of each case. For example, if the ambient temperature of the housing where the printed circuit board PCB is located is likely to vary significantly, such as for example outdoor variations from summer to winter, it is better to define the threshold in terms of relative humidity.

With reference to <FIG>, the humidity sensing module according to the invention comprises a printed circuit board PCB connected to a voltage source (Vcc) having at least two electrically conductive layers L<NUM>. Ln, the first of the at least two layers is the ground plane L<NUM> and the other at least one layer L<NUM>. Ln is signal layer.

The voltage source may be a continuous or variable in time voltage source (Vcc).

The minimum number of layers of the printed circuit board PCB required for the invention is two: the ground plane L<NUM> and the signal layer L<NUM>. The total number of layers depends on the purpose for which the printed circuit board PCB is configured and it is not relevant for the invention.

The humidity sensing module according to the invention further comprises a new signal layer of the printed circuit board PCB, specific to the invention, in addition to the ground plane L<NUM> and the other at least one signal layer L<NUM>. Ln called the transistor layer LT.

The transistor layer LT may be placed in any position, as intermediate layer between the ground plane L<NUM> and the other at one signal layer L<NUM>. Ln, as illustrated in <FIG> or as an outer layer on any side of the printed circuit board PCB, as illustrated in <FIG>.

The selection of the position of the transistor layer LT is carried out based on technical considerations, such as efficiency of use of the space. As it is known that the outer layers are usually used for accommodating the electrical or electronical components, it may be more efficient to position the transistor layer LT as intermediate layer. The working of the invention is not affected by the position of the transistor layer LT.

The transistor layer LT and ground plane L<NUM> are connected to voltage source Vcc by two resistors R1, and R2 configured to work as a voltage divider. The ground plane L1 is connected to voltage source Vcc by a first resistor R1 and a second resistor R2, and transistor layer LT is connected to said voltage source Vcc between first resistor R1 and the second resistor R2.

The electrical resistivity values of the first resistor R1 and, respectively of the second resistor R2 are selected depending on the required sensitivity of the humidity sensing module.

With reference to <FIG>, the humidity sensing module electric circuit further comprises a plurality of vias Vi+, Vi-arranged in pairs. The pairs of vias are placed in at least one pre-determined humidity-prone zone Zj of any of the outer surfaces of the two outer layers of the printed circuit board PCB at a pre-determined distance d, one from another.

Said plurality of vias Vi+, Vi- are specific to the invention, being added supplementary to any other vias that are accommodated within the printed circuit board PCB for functionality purposes of said printed circuit board PCB.

In order to allow the configurations of the plurality of vias Vi+, Vi- said transistor layer (LT) is configured to accommodate the plurality of positive vias (Vi+), whereas said ground plane (L<NUM>) is configured to accommodate the plurality of negative vias (Vi-).

The specific configurations of the plurality of vias Vi+, Vi- are as follows:.

Thus, one of the two ends of each via Vi+, Vi- reaches the same outer surface, whereas the other end of each via reaches the transistor layer LT, if the via is the positive one Vi+, or the ground layer (L1), if the via is the negative one Vi-.

The principle of the invention is to provide the plurality of vias Vi+, Vi- arranged in pairs, each via of the pair having one respective end configured as sensing elements such that, when the humidity threshold is exceeded on at least one humidity sensing areas from the at least one pre-determined humidity-prone zone Zj, the vias Vi+ and Vi-, placed at a predetermined distance d, become electrically connected determining a different voltage level between said resistors R1, R2. ) depending on the level of humidity exceeding predetermined threshold.

An external decision taking module µC is connected between said two resistors R1, R2 being configured to read the signal and interpret it depending on the different voltage level between said resistors (R1, R2).

In case pre-determined humidity-prone zones Zj are defined on both outer surfaces, such as the case illustrated in <FIG>, there is an electrical connection between the positive vias Vi+ connecting the transistor layer LT, respectively the negative via Vi- connecting ground plane L<NUM> with one of the outer surfaces and the positive vias Vi+ connecting the transistor layer LT, respectively the negative via Vi- connecting ground plane L<NUM> with the other outer surface. The electrical connection between vias is in particular advantageous, creating an efficient humidity sensing module, since it allows detection of the humidity in a short time from the moment of exceeding of the humidity threshold, on any of humidity-prone zones Zj defined on any of the both outer surfaces, and using the same components for all positive vias Vi+, and for all negative vias Vi-.

When the printed circuit board PCB is configured for future use, the pairs of vias Vi+, Vi- are placed in the at least one pre-determined humidity-prone zone Zj, any of them covering said zone uniformly or not uniformly.

When humidity increases in the at least one pre-determined humidity-prone zone Zj over the pre-determined humidity threshold, irrespective of whether humidity is vapour or water, there are two situations:.

In both cases, when humidity is below said pre-determined humidity threshold, the air between the positive via Vi+ and the negative via Vi-, respectively Vk- acts as a dielectric between the positive via Vi+ and the negative via Vi-. When humidity raises, the insulation capability of the air as dielectric drops to a critical point corresponding to the pre-determined humidity threshold, where due to the electrical conductivity phenomenon, the air can no longer insulate the positive via Vi+ from the negative via Vi- respectively Vk- and, consequently said vias Vi+ and Vi-, or respectively Vi+ and Vk- becomes electrically connected and further connected to the humidity sensing module electrical circuit, creating a different voltage level between resistors R1 and R2. Further, on the external decision taking module µC which is connected between said two resistors R1, R2 reads the signal and interprets it in order to take the appropriate decisions.

The plurality of vias is configured in respect to the required level of sensitivity depending on the particulars of each printed circuit board PCB, having the advantage of increased flexibility in sensing various levels of humidity.

The following features of the plurality of vias contribute to the sensitivity of the humidity sensing module:.

The distance d has usual values as accepted in the industry.

The greater the distance d between the positive via Vi+ and the negative via Vi- of each pair, the greater the width of the dielectric and a higher threshold of humidity is necessary to trigger conductivity, thus the less sensitive the humidity sensing module. On the contrary, the smaller the distance d between the positive via Vi+ and the negative via Vi- of each pair, the smaller the width of the dielectric and a lower threshold of humidity is necessary to trigger conductivity, thus more sensitive the humidity sensing module.

Having in view the cumulative effect of the electrical conductivity phenomenon, the more pairs of vias, the more sensitive the humidity sensing module is, because by adding the values of the dielectric strength of the pairs, the same humidity threshold is reached earlier. On the contrary, the less pairs of vias, the less sensitive the humidity sensing module. The minimum number of pairs for each pre-determined humidity-prone zone Zj is one pair.

The larger each pre-determined humidity-prone zone Zj is and/or the more pre-determined humidity-prone zones Zi are, the more sensitive the humidity sensing module is because by adding the values of the dielectric of the pairs, the same humidity threshold is reached earlier. It may be possible that one humidity-prone zone Zj be the entire surface of any outer surface or of both outer surfaces of the printed circuit board PCB, for example in case the printed circuit board PCB is placed in a sub-assembly heavily exposed to humidity.

In <FIG> a non-limiting example is illustrated where:.

Once the vias Vi+ and Vi-, placed at a predetermined distance (d) between them, irrespectively of whether they belong to the same pair or not, become electrically connected, due to humidity effects determine a signal of different voltage level between said resistors (R1, R2) depending on the level of humidity exceeding a predetermined threshold and thus allowing said signal to be read and interpreted by said external decision taking module (µC).

In a preferred embodiment of the invention, the specific signal depending on the voltage between the two resistors read by the external decision taking module µC is an analogical signal having a value which varies directly proportional with humidity level between the positive via (Vi+) and negative vias (Vi-) placed at said predetermined distance (d).

In a preferred embodiment, the humidity sensing module according to the invention, as it is shown in the <FIG>, further comprises a transistor T which is connected with its emitter to said voltage source Vcc by first resistor R1, with its collector directly connected to said ground plane L<NUM> and its base directly connected to transistor layer LT.

The second resistor R2 is connected in this case between emitter and base of said transistor T, keeping the direct connection between base and Transistor layer LT.

The transistor T is thus configured to work as a switch from Open Switch to Close Switch and from Close Switch to Open Switch depending on the signal received in base, signal which is dependent on the humidity.

Once humidity drops below the humidity threshold, the air between the vias Vi+ and Vi- of the same pair or respectively Vi+ and Vk- plays again its role of dielectric and the transistor T is operated from Close Switch to Open Switch and there is no more electric current flowing through the humidity sensing module electric circuit.

External decision taking module µC is configured to receive signal on the operation of the transistor T from Open Switch to Close Switch and from Close Switch to Open Switch, and to commute between two digital values:.

The first digital value corresponding to the operation Close Switch of said transistor T further corresponds to the exceeding of the humidity threshold, whereas the second digital value corresponding to the operation Open Switch of said transistor T further corresponds to not exceeding said humidity threshold.

The configuration of external decision taking module µC allows the possibility to read the signal and interpret it depending on the different voltage level between said resistors (R1, R2).

In an embodiment of the invention, the external decision taking module µC, may be a micro-controller or a logical gate. The selection of the type of external decision taking module µC depends on the characteristics and the functions of the printed circuit board PCB and of the sub-assembly where said printed circuit board PCB is used. For example, if a logical gate already exists in said sub-assembly carrying out other functions, it can be further configured to be used for the purpose of including it in the humidity sensing module electric circuit. In other situations, it may be preferable to use a dedicated micro-controller, for example in case there are many pre-determined humidity- prone zones Zj.

The advantage of the invention to be very flexible in sensing of the humidity stems by the possibility to define a wide range of humidity thresholds and zones while configuring the layers of each printed circuit board PCB.

In some situations, additional flexibility and wider sensitivity of the humidity sensing module can be obtained after the configuration of said printed circuit board PCB by adding other electrical components to the humidity sensing module electric circuit.

In another preferred embodiment, a resistor R3 is connected to the base of the transistor to provide stability of the signal, and at least a capacitor C1 between the ground plane L1 and the Transistor layer LT to filter the signal.

The invention discloses in a second aspect a hydrolysis prevention module comprising the humidity sensing module as described above in any of its embodiments, wherein the external decision taking module (µC) is configured to disconnect the current flow in at least one pre-determined humidity-prone zone Zj of at least one of the outer surfaces of the two outer layers of a printed circuit board (PCB) in order to limit the effect of hydrolysis on at least one pre-determined humidity-prone zone Zj of said printed circuit board (PCB) when the level of humidity exceeds a predetermined threshold.

In addition, since the humidity sensor makes use of components that are already present in a wide range of sub-assembly of various electronic control units embedded systems, such as the printed circuit board PCB, or are common for most industries: resistors, capacitors, switches, the humidity sensor has the economic advantage of being economically efficient.

The invention discloses in a third aspect a humidity sensor comprising the humidity sensing module as described above in any of its embodiments. The humidity sensor has all the advantages of the humidity sensing module. Alternatively, the humidity sensor may comprise said hydrolysis prevention module, having all the advantages mentioned above.

The external decision taking module µC may send the results of its interpretation to a display providing information regarding the level of humidity on the at least one pre-determined humidity-prone zone Zj of at least one of the outer surfaces of the two outer layers of a printed circuit board (PCB).

Claim 1:
Humidity sensing module for detecting humidity on at least one pre-determined humidity-prone zone Zj of at least one of the outer surfaces of the two outer layers of a printed circuit board (PCB), said printed circuit board (PCB) being connected to a voltage source (Vcc), and comprising:
- at least two electrically conductive layers (L<NUM>... Ln) :
• the first of the at least two electrically conductive layers being the ground plane (L<NUM>) and
• the other of at least two electrically conductive layer being a signal layer (L<NUM>...Ln) supporting electrical or electronical components
wherein said humidity sensing module further comprises:
- a transistor layer (LT) as a further signal layer, said transistor layer (LT) and said ground plane (L1) being connected to said voltage source (Vcc) by two resistors (R1, R2) configured to work as a voltage divider such us :
• said ground plane (L1) is connected to voltage source (Vcc) by a first resistor (R1) and a second resistor (R2), and
• said transistor layer (LT) is connected to said voltage source (Vcc) between said first resistor (R1) and said second resistor (R2),
- a plurality of vias (Vi+, Vi-) arranged in pairs, such that:
• the positive via of each pair (Vi+) has an end connected to at least one pre-determined humidity-prone zone Zj of one of the outer surfaces of the two outer layers and the other end connected to said transistor layer (LT);
• the negative via of each pair (Vi-) has an end connected to at least one pre-determined humidity-prone zone Zj of the same outer surface of the two outer layers and the other end connected to said ground plane (L<NUM>);
- an external decision taking module (µC) connected between said two resistors (R1, R2), being configured to read the signal and interpret it depending on the different voltage level between said resistors (R1, R2),
said humidity sensing module being configured such that when humidity between a positive via (Vi+) and a negative via (Vi-), placed at a predetermined distance (d) between them on the same outer surface, exceeds a humidity threshold, they become electrically connected determining a signal of different voltage level between said resistors (R1, R2) depending on the level of humidity and thus allowing said signal to be read and interpreted by said external decision taking module (µC).