Patent Description:
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, <CIT> 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.

In this connection, document <CIT> discloses a circuit board for a valve block of a solenoid valve manifold. Each valve block contains a valve which is actuated by either one single solenoid or by two solenoids. Both sides of the circuit board are provided with a circuit. The first surface - marked e.g. with an "S" - of the circuit board carries a single type valve circuit for supplying one single solenoid with electrical energy. The second surface - marked e.g. with a "D" - of the circuit board carries a double-type valve circuit for supplying two solenoids with electrical power. The circuit board is positioned in the respective valve block with the first surface or the second surface facing upwards depending on whether a single- or a double-solenoid-valve is used in the respective valve block.

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.

The above object is solved by the features specified in claims <NUM> and <NUM>, respectively. Advantageous and appropriate developments of the invention form the subject matter of claims <NUM> to <NUM>.

According to the present invention, a circuit board assembly for a fluid valve manifold comprises 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 has a set of conductive valve lines connected to and extending between a set of first electrical connectors and a set of second electrical connectors at opposite first and second ends of the circuit board. Further, the circuit board assembly is reversibly mountable to a first position or a second position to the fluid valve manifold such that a respective set of the first electrical connectors at the first end or a set of the second electrical connectors at the second end opposite that of the first end may be in position to receive electrical signals through the respective electrical connectors. At least one conductive valve line extends from a respective first electrical connector to a third connector on the surface of the circuit board operably leading to one voltage side of one of the at least one valve unit to serve a single solenoid valve unit, with a conductive common line connected to the third connector being operably connected to an opposite voltage side of the single solenoid valve unit and also connected to the first electrical connector and the second electrical connector when the circuit board assembly is in the first position. Furthermore, two conductive valve lines extend from respective second electrical connectors to the third connector leading to one voltage side of one of the at least one valve unit to serve a double solenoid valve unit, with a conductive common line connected to the third connector being operable connected to an opposite voltage side of the double solenoid valve unit and also connected to the first electrical connector and the second electrical connector when the circuit board assembly is in the second position.

Preferably, the third connector is mounted on the surface of the circuit board at a central longitudinal axis of the circuit board.

In this case, preferably, a plurality of third connectors all are mounted along the central longitudinal axis of the circuit board and are symmetrically positioned about a central transverse axis along a width of the circuit board.

In one preferred embodiment, the set of conductive valve lines comprises a set of single solenoid valve lines extending from the first electrical connectors and decremented one step for each third connector on the circuit board to the second electrical connectors, wherein the set of conductive valve lines comprises a set of double solenoid valve lines extending from the second electrical connectors and decremented two steps for each third connector on the circuit board to the first electrical connectors.

In this case, preferably, the second electrical connectors of the printed circuit board are constructed to be connectable to first electrical connectors of a sequentially connected printed circuit board, wherein the first electrical connectors of the printed circuit board are constructed to be connectable to second electrical connectors of a sequentially connected printed circuit board.

Further, preferably, the set of single solenoid valve lines and the set of double solenoid valve lines are on the surface of the circuit board.

Furthermore, preferably, the set of single solenoid valve lines and the set of double solenoid valve lines each is on respective opposite surfaces of the circuit board.

In one preferred embodiment, a communication circuit line is on the surface of the circuit board, extending from one of the first electrical connectors and to one of the second electrical connectors without any decrementation.

Finally, according to the present invention, a fluid valve manifold comprises an electrical conduit extending therethrough and a circuit board assembly as described above, that is received in the electrical conduit and actuates a plurality of valve units mounted to the fluid valve manifold.

Reference now is made to the accompanying drawings in which:.

Referring now to <FIG>, a fluid control system <NUM> is modular in nature and depending on the application has a varying number of valve manifold blocks <NUM> interconnected together. Only four valve manifold blocks <NUM> with eight valve units <NUM> are shown for simplicity of the drawings, i.e. each valve manifold block <NUM> mounts two valve units <NUM>. Some of the valve units <NUM> may be single solenoid operated and some valve units <NUM> may be double solenoid operated. Double solenoid valve units are also referred to as dual solenoid valves. All valve manifold blocks <NUM> are operably connected to a communication module <NUM>.

Preferably, each valve manifold block <NUM> may accommodate two valve units <NUM> each being a single or double solenoid variety. It is possible that the valve manifold block <NUM> can mount one valve unit <NUM> of the single solenoid variety and one valve unit <NUM> of the double solenoid variety. Each valve manifold block <NUM> has a passage <NUM> that receives a printed circuit board assembly <NUM> which will be described in more detail.

Referring now to <FIG> and <FIG>, the printed circuit board assembly <NUM> has a printed circuit board <NUM> with pin connectors <NUM>, <NUM>, <NUM>, and <NUM> (often called J-pin connectors) mounted on a front surface <NUM> of the printed circuit board <NUM>. Each pin connector is symmetrically mounted along a central longitudinal axis <NUM> of the printed circuit board <NUM>. Further, the set of pin connectors <NUM>-<NUM> are symmetrically positioned about a minor transverse axis <NUM> of the printed circuit board <NUM>. Preferably, the J-pin connectors are equally spaced as well as symmetrically positioned relative to the minor transverse axis <NUM> to accommodate uniformly spaced and positioned valve units <NUM>. This symmetry provides that the printed circuit board assembly <NUM> can rotate about an axis <NUM> that passes through the thickness of the printed circuit board <NUM> and is transverse to both the central longitudinal axis <NUM> and the minor transverse axis <NUM> as described in more detail later.

Each printed circuit board <NUM> has a first edge <NUM> and a second edge <NUM> with respective connectors in the form of electrical contacts <NUM> and <NUM>. These electrical contacts <NUM> and <NUM> may be traces printed directly on the printed circuit board <NUM>. The electrical contacts <NUM> and <NUM> are connected together by lines <NUM> also in the form of traces. As shown in <FIG>, a standard bridge connector <NUM> electrically connects the aligned electrical contacts <NUM> and <NUM> of adjacent printed circuit boards <NUM> shown in <FIG> within the bridge connectors <NUM>.

Referring now to <FIG> and <FIG>, the electrical contacts <NUM>, <NUM>, and lines <NUM> may be on both the front surface <NUM> and a rear surface <NUM> of the printed circuit board <NUM>. The electrical contacts <NUM>, <NUM> and lines <NUM> are generally arranged to accommodate both single and double solenoid valves depending on how the printed circuit board <NUM> is installed. As shown in <FIG>, the electrical contacts <NUM> each have a specific position labeled A1, A2, A3 and connect to lines <NUM> on the printed circuit board <NUM>. The illustrated printed circuit board <NUM> shows a capacity of thirty (<NUM>) electrical contacts at each edge <NUM> and <NUM> which indicates the valve manifold block <NUM> using that printed circuit board <NUM> is limited to a maximum of thirty single solenoid valves. The electrical contacts <NUM>, <NUM> are also symmetrically spaced about the central longitudinal axis <NUM>. The printed circuit boards <NUM> can be traced with more or less electrical contacts and lines depending on the needed capacity and applications of the end user as long as the electrical contacts are symmetrically spaced about the central longitudinal axis <NUM>.

The first four electrical contacts A1-A4 lead to respective first pin socket contacts <NUM> at respective pin connectors <NUM>, <NUM>, <NUM>, and <NUM>. Each first pin socket contact <NUM> is connectable to the respective solenoid valve unit <NUM> of the single solenoid variety. Each solenoid valve unit <NUM> is also respectively connected to a pin socket contact <NUM> which is connected to a common voltage line <NUM> that leads to an electrical contact Vcomm with a common voltage. The Vcomm electrical contacts are normally connected to a <NUM> volt supply to power all of the valve units <NUM> when the circuit is completed. As shown, the first four electrical contacts A1-A4 and the respective lines <NUM> are on the same front surface <NUM> of the printed circuit board <NUM>.

The remainder of the conductive valve lines <NUM> labeled A5-A30 on both surfaces <NUM> and <NUM> extend from the first edge <NUM> to the second edge <NUM> and may be decremented four steps or positions from edge <NUM> to edge <NUM>, i.e. one step for each valve unit <NUM> of the single solenoid type. For example (cf. <FIG>), see valve line A5 that leads to the electrical contact B15 which can then connect to the electrical contact A1 or B1 in a subsequent printed circuit board <NUM> depending on the rotated position of the subsequent printed circuit board <NUM>.

Other lines <NUM> at the bottom of the printed circuit board <NUM> can provide auxiliary power lines or function as a protective earth line or function as a serial communication line. Line <NUM> as well as the Vcomm common voltage line <NUM> extend through the printed circuit board <NUM> without any decrementation of position.

Referring now to <FIG> describing the second edge <NUM>, which when the printed circuit board <NUM> is rotated <NUM> degrees about the axis <NUM> becomes the left edge, the two electrical contacts <NUM> labeled B1 and B2 are connected to the pin connector <NUM>, the electrical contacts <NUM> labeled B3 and B4 are connected to the pin connector <NUM>, the electrical contacts <NUM> labeled B5 and B6 are connected to the pin connector <NUM> and the electrical contacts <NUM> labeled B7 and B8 are connected to the pin connector <NUM>. The respective electrical contacts B1, B3, B5 and B7 are connected to the first pin socket contact <NUM> of each respective pin connector <NUM>, <NUM>, <NUM>, and <NUM>, while the electrical contacts B2, B4, B6 and B8 are connected to a third pin socket contact <NUM> of each respective pin connector <NUM>, <NUM>, <NUM>, and <NUM>.

The pin socket contacts <NUM> and <NUM> are connected to the respective solenoids of each double solenoid valve unit <NUM>. Line <NUM> which now is in the position to carry the common voltage is operably connectable to the opposite voltage side of each solenoid. Each solenoid valve unit <NUM> is also respectively connected to pin socket contact <NUM> which is now in the lower right position as shown in <FIG> to connect to the line <NUM> that is in the position to carry the common voltage.

The remainder of the conductive electrical contacts <NUM> and lines <NUM> labeled B9-B30 on both surfaces <NUM> and <NUM> extend from the second edge <NUM> to the first edge <NUM> and are decremented eight steps or positions from the first edge <NUM> to the second edge <NUM>, i.e. two steps for each valve unit <NUM> of the double solenoid type. For example (cf. <FIG>), see contact B9 which has its line stepped to contact A15 which can then connect to contact B1 in a subsequent printed circuit board <NUM>. The line <NUM> which functioned as the common voltage line for the single solenoid valves can now function as an auxiliary power line, function as a protective earth line, or a rapid communication line.

The trace lines <NUM> leading to the contacts A6-A30 and B10-B30 have been omitted to simplify and clarify the drawings. These trace lines can be stepped and also switched from the front surface <NUM> to the rear surface <NUM> and back again as needed. It is also foreseeable that the line <NUM> or <NUM> depending on the rotated orientation of the printed circuit board <NUM> about axis <NUM> can also function as a detection line that can be used to determine if the printed circuit board is a single board or a double board. The layout of the contacts A5-A30 and B8-B30 that do not connect to the pin connectors <NUM>-<NUM>, the detection line, and the single serial communication line are fully described in <CIT> to DeCarolis which is hereby incorporated by reference. In addition, an appropriate label "single" or "double" is placed in proximity to the respective edge <NUM> and <NUM>.

Referring now to <FIG>, an alternative embodiment is shown. In this embodiment, a fluid control assembly <NUM> may have an integrally formed valve manifold block <NUM> with valve units <NUM> mounted on top. A communication module <NUM> may be mounted near one end. A single printed circuit board <NUM> shown in <FIG> may extend through the entire valve manifold block <NUM>. The main difference between this embodiment and the previously described embodiment is that instead of edge contacts or edge traces <NUM> and <NUM>, the printed circuit board <NUM> has pin connectors <NUM> and <NUM> at each end that connect to traces <NUM>. The pin connectors <NUM> and <NUM> are mounted on the same surface as J-pin connectors <NUM>, <NUM>, <NUM>, and <NUM>. The J-pin connectors <NUM>-<NUM> are at a <NUM>° rotated angle but still provide the needed symmetry about both a longitudinal axis <NUM> and a transverse axis <NUM>. Extra pin contacts are spares and are there for longer printed circuit boards with more valve stations. Each printed circuit board has at each edge <NUM> and <NUM> a separate pin connector <NUM> and <NUM> that can be used to attach to additional valve units <NUM> connected through other printed circuit boards. Only two traces <NUM> are shown extending out of each separate pin connector <NUM> and <NUM>. Up to six traces for each round pin connector can extend between the pin connectors <NUM> and <NUM> and between the pin connectors <NUM> and <NUM>.

Each edge <NUM> and <NUM> 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 <NUM>. Other indications such as a single notch <NUM> or double notch <NUM> can also be placed at a respective edge <NUM> and <NUM> to indicate the single or double valve application.

The advantage of either reversible embodiment is that the printed circuit board can be used for single valve units or double valve units by proper rotation of the printed circuit board. The valve manifold block can have both single and double valve units in any desired order with the proposed rotation of each printed circuit board in the valve manifold block. Furthermore, these printed circuit boards can be attached to other printed circuit boards either via the bridge connector <NUM> or through pin connectors. In addition, these reversible printed circuit boards can also be used in conjunction with standard non-reversible commercially available printed circuit boards of either the single or double valve station variants.

Claim 1:
A circuit board assembly (<NUM>) for a fluid valve manifold (<NUM>), comprising:
a plurality of connectors (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) on a surface (<NUM>, <NUM>) of a circuit board (<NUM>) for connection to at least one valve unit (<NUM>) mounted to said fluid valve manifold (<NUM>) ;
said circuit board (<NUM>) having a set of conductive valve lines (<NUM>) connected to and extending between a set of first electrical connectors (<NUM>) and a set of second electrical connectors (<NUM>) at opposite first and second ends (<NUM>, <NUM>) of said circuit board (<NUM>);
said circuit board assembly (<NUM>) being reversibly mountable to a first position or a second position to said fluid valve manifold (<NUM>) such that a respective set of said first electrical connectors (<NUM>) at said first end (<NUM>) or a set of said second electrical connectors (<NUM>) at said second end (<NUM>) opposite that of said first end (<NUM>) may be in position to receive electrical signals through said respective electrical connectors (<NUM>, <NUM>);
at least one conductive valve line (<NUM>) extending from a respective first electrical connector (<NUM>) to a third connector (<NUM>, <NUM>, <NUM>, <NUM>) on said surface (<NUM>, <NUM>) of said circuit board (<NUM>) operably leading to one voltage side of one of said at least one valve unit (<NUM>) to serve a single solenoid valve unit with a conductive common line (<NUM>) connected to said third connector (<NUM>, <NUM>, <NUM>, <NUM>) being operably connected to an opposite voltage side of said single solenoid valve unit and also connected to said first electrical connector (<NUM>) and said second electrical connector (<NUM>) when said circuit board assembly (<NUM>) is in said first position; and
two conductive valve lines (<NUM>) extending from respective second electrical connectors (<NUM>) to said third connector (<NUM>, <NUM>, <NUM>, <NUM>) leading to one voltage side of one of said at least one valve unit (<NUM>) to serve a double solenoid valve unit with a conductive common line (<NUM>) connected to said third connector (<NUM>, <NUM>, <NUM>, <NUM>) being operable connected to an opposite voltage side of said double solenoid valve unit and also connected to said first electrical connector (<NUM>) and said second electrical connector (<NUM>) when said circuit board assembly (<NUM>) is in said second position.