U.S. patent application number 12/526030 was filed with the patent office on 2010-12-02 for high voltage recessed connector contact.
This patent application is currently assigned to LHV POWER CORPORATION. Invention is credited to Scott T. Carroll, Kenneth E. Wing.
Application Number | 20100302746 12/526030 |
Document ID | / |
Family ID | 39682105 |
Filed Date | 2010-12-02 |
United States Patent
Application |
20100302746 |
Kind Code |
A1 |
Wing; Kenneth E. ; et
al. |
December 2, 2010 |
HIGH VOLTAGE RECESSED CONNECTOR CONTACT
Abstract
A process relating to a one step low pressure injection molding
method of encapsulating high voltage circuitry while incorporating
a unique recessed high voltage connector contact means within the
injection molding material, greatly reducing the component size,
while increasing the capabilities of this type of circuitry. The
process reduces the manufacturing time and maintains a clean sealed
contact point for repeated usage by the means of a conductive
rubber slug. An additional advantage is by creating cavities
through the circuit board; axially leaded high voltage components
may be conveniently mounted without additional assembly components
while being fully encapsulated.
Inventors: |
Wing; Kenneth E.; (Alpine,
CA) ; Carroll; Scott T.; (Lakeside, CA) |
Correspondence
Address: |
RICHARD D. CLARKE;LAW OFFICE OF RICHARD D. CLARKE
3755 AVOCADO BLVD., #1000
LA MESA
CA
91941-7301
US
|
Assignee: |
LHV POWER CORPORATION
Santee
CA
|
Family ID: |
39682105 |
Appl. No.: |
12/526030 |
Filed: |
February 6, 2008 |
PCT Filed: |
February 6, 2008 |
PCT NO: |
PCT/US08/53227 |
371 Date: |
August 5, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60899783 |
Feb 6, 2007 |
|
|
|
Current U.S.
Class: |
361/760 ; 29/829;
439/78 |
Current CPC
Class: |
H05K 2201/09063
20130101; Y10T 29/4913 20150115; H05K 1/182 20130101; H05K
2201/10189 20130101; H05K 2201/10651 20130101; H05K 3/3421
20130101; B29C 45/14639 20130101; Y10T 29/49146 20150115; H01R
2101/00 20130101; H05K 1/0254 20130101; H01R 24/76 20130101; Y10T
29/49124 20150115; H01R 13/5219 20130101; H05K 2203/1316 20130101;
H05K 3/284 20130101; H01R 13/53 20130101; Y10T 29/49155
20150115 |
Class at
Publication: |
361/760 ; 439/78;
29/829 |
International
Class: |
H05K 7/00 20060101
H05K007/00; H01R 12/30 20060101 H01R012/30; H05K 3/00 20060101
H05K003/00 |
Claims
1. An over-molded printed circuit board (PCB) with an integrated
poke-home connector comprising: (a) a deeply recessed high voltage
connector contact, having a conductive rubber slug and a thin
membrane over said recessed conductive rubber slug whereby said
recessed high voltage connector contact forms an arc and leakage
resistant connection point.
2. An over-molded printed circuit board (PCB) with an integrated
poke-home connector comprising: (a) a low pressure over-molded
encapsulation potting a high voltage multiplier PCB with an
integrated high voltage transformer; (b) a deeply recessed high
voltage connector contact, having a conductive rubber slug and a
thin membrane over said recessed conductive rubber slug; (c) slots
cut into the PCB to allow for standard surface mounting techniques
for mounting components onto the PCB; and (d) components selected
for their use in current mode (CM) output control of the high
voltage output curves slope; whereby the over-molded PCB with an
integrated poke-home connector can safely and efficiently deliver
high voltage to an object inserted into said deeply recessed high
voltage connector contact.
3. A method for making the over-molded PCB with an entegrated
poke-home connector, constructed in accordance with claim 1,
comprising the steps of: a) providing a low pressure over-molded
encapsulation potting of a high voltage multiplier PCB with an
integrated high voltage transformer; b) providing a deeply recessed
high voltage connector contact, having a conductive rubber slug and
a thin membrane over said recessed conductive rubber slug; c)
cutting slots into the PCB to allow for standard surface mounting
techniques for mounting components onto the PCB; and d) selecting
components for their use in current mode (CM) output control of the
high voltage output curve slope; whereby the over-molded PCB with
an integrated poke-home connector can safely and efficiently
deliver high voltage to an object inserted into said deeply
recessed high voltage connector contact.
4. An over-molded printed circuit board (PCB) with an integrated
poke-home connector according to claim 1, further comprising: (a) a
plurality of integrated current mode control components; (b) a low
pressure over-molded encapsulation potting said plurality of
components mounted on a high voltage PCB; and (c) a deeply recessed
high voltage connector contact affixed to said PCB, having a
conductive rubber slug and a thin membrane over said recessed
conductive rubber slug; whereby said recessed high voltage
connector contact forms an arc and leakage resistant connection
point.
5. The PCB according to claim 1, further comprising: a metal saddle
electrically connected to said PCB; wherein said recessed
conductive rubber plug is electrically connected to said metal
saddle.
6. The PCB according to claim 1, further comprising: slots cut into
said PCB to allow for standard surface mounting techniques for
mounting said plurality of components onto said PCB.
7. The PCB according to claim 6, wherein at least one of said
plurality of components further comprise axially mounted
components.
8. The PCB according to claim 1, further comprising: cavities cut
into said PCB to allow for standard surface mounting techniques for
mounting said plurality of components onto said PCB.
9. The PCB according to claim 8, wherein at least one of said
plurality of components further comprise large surface area
components.
10. The PCB according to claim 1, further comprising: channels cut
into said PCB to allow the encapsulation material to fill said
channels breaking the conduction path along the surface of said PCB
between said plurality of components.
11. The PCB according to claim 1, wherein at least one of said
plurality of components is a high voltage component.
12. The PCB according to claim 11, wherein the high voltage
component is high voltage multiplier with an early voltage sensing
divider.
13. The PCB according to claim 1, wherein at least one of said
plurality of components may be used for current mode (CM) output
control of the high voltage output curve slope.
14. A method for making an over-molded PCB with an integrated
poke-home connector, comprising the steps of: (a) providing a
printed circuit board (PCB); (b) cutting a plurality of openings in
said PCB; (c) providing a plurality of components; (d) mounting
said plurality of components in said plurality of openings; (e)
providing an arc and leakage resistant connection point; and (f)
encapsulating said components and said PCB by means of a low
pressure injection molding; whereby the part is fully encapsulated
and has maintained overall minimum width.
15. The method for making an over-molded PCB with an integrated
poke-home connector according to claim 14, wherein the step of
providing said arc and leakage resistant connection point further
comprises the step of providing a deeply recessed high voltage
connector contact affixed to said PCB, having a conductive rubber
slug and a thin membrane over said recessed conductive rubber
slug.
16. The method for making an over-molded PCB with an integrated
poke-home connector according to claim 15, further comprising the
step of: providing a metal saddle electrically connected to said
PCB; wherein said recessed conductive rubber plug is electrically
connected to said metal saddle.
17. The method for making an over-molded PCB with an integrated
poke-home connector according to claim 14, wherein the plurality of
holes in the PCB further comprise channels in said PCB to allow the
encapsulation material to fill said channels breaking the
conduction path along the surface of said PCB between said
plurality of components.
Description
[0001] This patent application claims the benefit of U.S.
provisional patent application Ser. No. 60/899,783 filed on Feb. 6,
2007.
FIELD OF THE INVENTION
[0002] The process relates to a one step low pressure injection
molding method of encapsulating high voltage circuitry while
incorporating a unique integrated recessed high voltage connector
contact means, greatly reducing the component size, while
increasing the capabilities of this type of circuitry and
connection means. The process reduces the manufacturing time and
maintains a clean sealed contact point for repeated usage. An
additional advantage in this process is by creating cavities
through the circuit board; axially leaded high voltage components
may be conveniently mounted without additional assembly components
while being fully encapsulated.
BACKGROUND OF THE INVENTION
[0003] The standard technique of protecting high voltage circuitry
from the environment and from internal arcing, due to the necessity
to violate open air construction spacing rules while using compact
construction techniques with high voltage levels, entails
encapsulating the circuitry using an open potting shell or mold,
pouring in liquid state epoxy or RTV rubber, vacuum de-airing the
material, and then curing the assembly at room temperature for a
certain period of time. This traditional method requires many steps
and much time to complete, and is thus not well suited for high
volume, low cost assembly of high voltage circuit boards.
Therefore, it would be highly desirable to have an encapsulation
technique that would entail fewer steps, be more efficient and less
expensive to perform, as well as be suitable for high volume low
cost assembly of high voltage circuit boards.
[0004] High Voltage connections require long tracking distances and
the use of insulating material to prevent corona and electron
leakage from the point of connection. This is most often done by
deeply recessing an open contact point at the base of a long tunnel
of insulating material to form the "female" contact, with the male
contact being a long conductor point insulated by an appropriate
material, except at the point of connection at the bottom of the
tunnel. The common terminology for this is a "poke-home
connection". These connectors tend to be expensive and space
consuming. Therefore, it would be highly desirable to have a
connection tunnel that is integrated into the encapsulation
over-molding material including a built-in contact or other typical
conductive contact device, such as but not limited to a conductive
rubber slug.
[0005] The use of a conductive rubber slug to make an electrical
contact is not new, however, it would be highly desirable to have a
novel design which incorporates a metal "saddle" that by which the
slug is secured to the printed circuit board. This way, the saddle
is assembled and soldered to the printed circuit board by normal
surface mount assembly and soldering techniques, and the slug could
then be pushed in place into the saddle by another normal assembly
pick and place operation, saving time and expense. By this process
the rubber slug is additionally encapsulated with a thin cross
sectional area adjacent to the integrated poke-home connection
tunnel creating a thin membrane surface on that side.
[0006] Often in High Voltage work, surface mount components,
suitable for high voltage operation, of a specific size and
performance are not available, or if they are, they are
dramatically more expensive than the conventional "thru-hole"
counterpart. This is the case with a resistor used for high voltage
regulation feedback. The use of axially leaded components with
surface mount assembly techniques would normally require complex
lead formation devices and special tape cavity carriers to allow
for proper component alignment into the pick and place machinery
prior to placement on the board. Therefore, it would be highly
desirable to have a slot pre-cut into the printed circuit board
where the resistor or any other axially or conventionally leaded
component will mount in a recessed fashion to enable quick assembly
and complete encapsulation over the component and printed circuit
board.
[0007] Numerous innovations for encapsulating circuitry have been
provided in the prior art that are described as follows. Even
though these innovations may be suitable for the specific
individual purposes to which they address, they differ from the
present process as hereinafter contrasted. The following is a
summary of those patents most relevant to the description at hand,
as well as a description outlining the difference between the
features of the present process of encapsulating high voltage
circuitry with a connector contact means and those of the prior
art.
[0008] U.S. Pat. No. 7,211,215 of Mareel Gerardus Antonius Tomassen
et al. relates to a mold for encapsulating electronic components
mounted on a carrier, comprising: of at least two mold parts
displaceable relative to each other, at least one of which is
provided with a recess, and feed means for encapsulating material,
wherein at least one of the mold parts is provided with a runner
which connects on one side to a wall of a mold part co-defining a
mold cavity and connects on the other side to a side of the mold
part remote from the mold cavity. The invention also relates to an
encapsulating device of which such a mold forms parts, and to a
method for encapsulating electronic components mounted on a
carrier.
[0009] This patent describes a mold for encapsulating conventional
electronic components mounted on a carrier but does not deal with
the unique problems incurred with encapsulating high voltage
circuitry or the incorporation of contact means within the
encapsulating material or the use of a low pressure injection
molding encapsulating technique.
[0010] U.S. Pat. No. 6,534,711 of Richard Stephen Pollack describes
a package for encapsulating electronic components that has at least
two chambers. Electronic components and modules within the chambers
are interconnected by a lead frame extending between the two
chambers. One chamber may surround the other chamber, or it may be
adjacent the other chamber. The sidewall of one chamber may be
higher than the sidewall of the other chamber. Each of the chambers
may individually be filled with encapsulating material. Temporary
connections to the lead frame may be made after one chamber is
filled with encapsulating material, in an unfilled other chamber of
the package, which is subsequently filled with encapsulating
material. A portion of a lead frame may extend to the exterior of
the package. Openings may be provided in an external surface of the
package for making connections with external components. The
electronic components may include an RF-transponder and a pressure
sensor, and the package may be mounted within a pneumatic tire.
[0011] This patent describes a novel technique for packaging
electronic circuit modules and components. It does not use an
injection molding process or deal with the problems involved with
high voltage circuitry or the innovative way of creating a slot
pre-cut into the printed circuit board where the resistor or any
other axially or conventionally leaded component will mount in a
recessed fashion to enable quick assembly and complete
encapsulation.
[0012] U.S. Pat. No. 6,531,083 of Mario A. Bolanos et al. describes
a method and apparatus for encapsulating an integrated circuit die
and lead frame assembly. A prepackaged sproutless mold compound
insert is placed in a rectangular receptacle in a bottom mold
chase. The receptacle is coupled to a plurality of die cavities by
runners. Lead frame strip assemblies containing lead frames,
integrated circuit dies, and bond wires coupling the lead frames
and dies are placed over the bottom mold chase such that the
integrated circuit dies are each centered over a bottom mold die
cavity. A top mold chase is placed over the bottom mold chase and
the mold compound package. The top mold chase has die cavities
corresponding to those in the bottom mold chase. The mold compound
insert is preferably packaged in a plastic film, which has heat
sealed edges. The mold compound is forced through the package and
heat seals during the molding process by the pressure applied by a
rectangular plunger. The sproutless mold compound insert is
packaged so that the mold compound will exit the packaging only
where runners intersect the receptacle. The sproutless mold
compound insert requires no alignment or cutting tools within the
mold station. The plunger is applied using variable speed and
pressure to control the rate the mold compound fills the cavities
in the top and bottom mold chases, thereby avoiding voids in the
completed packages and minimizing wire sweep of the bond wires of
the integrated circuit assemblies.
[0013] This patent relates to the field of die and lead frame
assembly of integrated circuits and to the encapsulation packaging
using transfer-molding techniques which is a much slower process
than the low pressure injection molding process and less adaptable
to a rapid production. It does not incorporate the low-pressure
injection molding process, the conductive rubber slug or the
integrated connection tunnel.
[0014] U.S. Pat. No. 4,861,251 of Max Moitzger describes an
apparatus for encapsulating selected portions of the printed
circuit board in a pin grid array using transfer-molding
techniques. In one embodiment for encapsulating only the top
surface and side edges of the board, a vacuum is provided in the
lower cavity to hold the edges of the bottom surface of the board
flush against the mold plate. In a second embodiment for
encapsulating all exposed surfaces of the board, the array pins are
inserted in holes in the bottom of the cavity and supported by an
adjustable block which positions the board in the cavity.
[0015] This patent describes an apparatus for encapsulating
selected portions of conventional printed circuit boards but does
not deal with the unique problems involved with a high voltage
circuit board and does not include incorporating a means of
connection into the encapsulation material.
[0016] None of the foregoing prior art teaches or suggests the
particular unique features of encapsulating high voltage circuitry
incorporating a connector contact means and thus clarifies the need
for further improvements in the field of encapsulating high voltage
components.
[0017] In this respect, before explaining at least one embodiment
of the design in detail it is to be understood that the
encapsulating high voltage circuitry incorporating a connector
contact means is not limited in its application to the details of
construction and to the arrangement of the components set forth in
the following description or illustrated in the drawings. The
process is capable of other embodiments and of being practiced and
carried out in various ways. Also, it is to be understood that the
phraseology and terminology employed herein are for the purpose of
description and should not be regarded as limiting.
SUMMARY OF THE INVENTION
[0018] The principal advantage is to create a process of
encapsulating high voltage circuitry with a unique incorporated
connector contact means.
[0019] Another advantage is to use a low-pressure injection molding
technique to accelerate the manufacturing process.
[0020] Another advantage is to create an integrated poke-home
connection tunnel into the over-molding material used to
encapsulate the high voltage circuitry, saving the cost of the
connector, and the cost of mounting a separate connection means to
the circuit board assembly.
[0021] Another advantage is to mount a conductive rubber slug, by
the means of a metal saddle on the circuit board, covered by the
over-molding material and creating a thin membrane between the
conductive rubber slug and the integrated poke-home connection
tunnel.
[0022] Another advantage is having a thin membrane between the
conductive rubber slug and the incorporated connection poke-home
tunnel is that a mating insulated "male" high voltage connector
with a sharp point can easily penetrate the membrane making the
shielded high voltage electrical contact required.
[0023] And still another advantage is that the opening created in
the membrane will contract after the "male" high voltage connector
with a sharp point is removed re-sealing the conductive rubber slug
from the environment.
[0024] A further advantage is to have a slot pre-cut into the
printed circuit board where the resistor or any other axially or
conventionally leaded component will mount in a recessed fashion to
enable quick assembly and complete encapsulation required for the
high voltage assembly process.
[0025] Yet, another advantage is having the channels or slots cut
into the circuit board so the encapsulation material fills the
channels breaking the conduction path along the surface of the
circuit board between high voltage electrical components.
[0026] A final advantage is to add a new and unique high voltage,
compact, easily manufactured circuit board assembly to the field of
high voltage electrical components.
[0027] These together with other objects of this process, along
with the various features of novelty, which characterize the
encapsulating high voltage circuitry with a unique incorporated
connector contact means, are pointed out with particularity in the
claims annexed to and forming a part of this disclosure. For a
better understanding of the process, its operating advantages and
the specific objects attained by its uses, reference should be made
to the accompanying drawings and descriptive matter in which there
are illustrated preferred embodiments. There has thus been
outlined, rather broadly, the more important features in order that
the detailed description thereof that follows may be better
understood, and in order that the present contribution to the art
may be better appreciated. There are additional features that will
be described hereinafter and which will form the subject matter of
the claims appended hereto.
[0028] The preferred embodiment of the present process includes
encapsulation of high voltage circuitry by the means of over
molding the circuit board by a low-pressure injection molding
process with the incorporation of a high voltage electrical
poke-home connector contact tunnel. A unique design of the circuit
board will include slots, cavities and channels cut through
allowing resistors, or any other axially or conventionally leaded
components to drop down into the board and the leads of the part
rest on the solder coated pads at each end of the part. Before
taping the part on a reel for automatic insertion, a lead forming
machine cuts the leads of the axial part short, to 0.1'' long on
each end. Then the part is placed by the lead cutting machine onto
a tape reel. The circuit board is screened with solder paste, and
then the axial parts is placed into the holes by the pick and place
machine. The leads rest on the two solder coated pads, and the unit
is placed in a re-flow oven to melt the solder and complete the
joint of wires to pads, along with all the other components that
have been inserted. Channels cut in the circuit boards are centered
on the high voltage electrical components allowing the injection
molding resin to fully migrate into the slot and channels
encapsulating the components, even the bottom against the board,
which is necessary in order to break up a potential conduction path
along the surface of the board or the surface of the component
between the mounting pads. The unique channel design allows that
the high voltage components can be arranged closer together,
reducing the required size and making a more compact sealed
unit.
[0029] The printed circuit board is placed into a mold designed
specifically for it, and, using resin beads and an injection
molding machine designed for the low pressure molding resin, the
board is over-molded in one manufacturing step. The resultant unit
is a device that is fully protected from the environment, and also,
by the use of the proper circuit board design techniques, the high
voltage components inside are fully encapsulated and insulated from
each other, preventing internal arcing that would damage the parts
while also providing the ability to have a smaller more compact
device.
[0030] A high voltage electrical tapered poke-home connection
tunnel has been designed into the over-molding material used to
encapsulate the high voltage circuitry, saving the cost of the
connector, and the cost of mounting the connector to the circuit
board assembly. The mold has a tapered slide plug, which is
retracted after molding and the deep tapered recess tunnel is
formed directly into the over-mold structure covering the circuit
board.
[0031] A conductive rubber slug will be secured to the circuit
board by the means of a metal saddle attached to the circuit board
in the conventional soldering technique. The conductive rubber slug
is then pushed in place onto the saddle by another normal assembly
pick and place operation. The innovation here is the mounting of
the conductive rubber slug to a surface mount circuit board by
conventional machines and techniques, saving special assembly cost
and time.
[0032] The over-molding process produces a thin membrane layer of
the injection molding material over the contact surface of the
conductive rubber contact slug adjacent to the base of the
integrated high voltage poke-home connector tunnel. This thin
membrane serves to protect the slug surface from the environment
during storage and further assembly processing and serves to
prevent air contact after assembly. The "male" high voltage
connector contact is formed with a sharp point, so that when the
male and female portions of the connector are brought into place in
the overall device assembly, the male contact can pierce the
membrane, and then imbed into the conductive rubber slug. This
membrane serves to reduce air contact to the slug and the male
contact in this operation, thus reducing the opportunity for
damaging corona or electrical leakage to occur. The opening created
in the membrane will contract after the "male" high voltage
connector with a sharp point is removed re-sealing the conductive
rubber slug from the environment.
[0033] An alternate embodiment of encapsulating high voltage
circuitry incorporating a connector contact means will have the
metal saddle, conductive rubber slug contact and the integrated
high voltage poke-home connector tunnel located on the opposite
side of the circuit board. This design will shorten the overall
length of the unit and reduce the amount of injection molding
material required.
[0034] With respect to the above description then, it is to be
realized that the optimum dimensional relationships for the parts
of the process of encapsulating high voltage circuitry
incorporating a connector contact means, to include variations in
size, materials, shape, form, function and manner of operation,
assembly and use, are deemed readily apparent and obvious to one
skilled in the art, and all equivalent relationships to those
illustrated in the drawings and described in the specification are
intended to be encompassed by the present description. Therefore,
the foregoing is considered as illustrative only of the principles
of the process. Further, since numerous modifications and changes
will readily occur to those skilled in the art, it is not desired
to limit the design to the exact construction and operation shown
and described, and accordingly, all suitable modifications and
equivalents may be resorted to, falling within the scope of the
design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The accompanying drawings, which are incorporated in and
form a part of this specification, illustrate embodiments of the
encapsulated high voltage circuit board incorporating the connector
tunnel and together with the description, serve to explain the
principles of this invention.
[0036] FIG. 1 depicts a top view of a typical encapsulated high
voltage circuit board incorporating the connector contact
means.
[0037] FIG. 2 depicts an end view of a typical encapsulated high
voltage circuit board incorporating the connector contact means
illustrating the external connection means.
[0038] FIG. 3 depicts a side view of a typical encapsulated high
voltage circuit board incorporating the connector contact
means.
[0039] FIG. 4 depicts an end view of a typical encapsulated high
voltage circuit board illustrating the incorporated connector
contact means.
[0040] FIG. 5 depicts a cross section of a typical encapsulated
high voltage circuit board incorporating the connector contact
means with conventional mold housing and tapered tunnel plug and
the "male" high voltage connector.
[0041] FIG. 6 depicts a perspective view of the high voltage
circuit board illustrating the pre-cut slots, cavities and channels
enabling the unique installation of high voltage components while
achieving complete coverage and isolation by the encapsulating
materials.
[0042] FIG. 7 depicts a cross section of a portion of a circuit
board illustrating the location in the pre-cut slot of a high
voltage resistor and the encapsulating material.
[0043] FIG. 8 depicts a cross section of a portion of a circuit
board illustrating the location of high voltage electrical
component raised off the board by the means of a bead of epoxy and
covered with the encapsulating material.
[0044] FIG. 9 depicts a perspective view of a typical encapsulated
high voltage circuit board incorporating the connector contact
means with a portion of the encapsulating material removed.
[0045] FIG. 10 depicts a perspective view of a typical encapsulated
high voltage circuit board incorporating the connector contact
means.
[0046] FIG. 11 depicts an alternate embodiment of the encapsulated
high voltage circuit board incorporating the connector contact
means with the conductive rubber slug, metal saddle and the tapered
"poke-home connection" tunnel on the opposite side of the circuit
board.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Referring now to the drawings, wherein similar parts of the
process are identified by like reference numerals, there is seen in
FIG. 1 a top view of a typical encapsulated high voltage circuit
board incorporating the connector contact means 10A where the main
body section 12 is shown with the external electrical connector 14
on the left. On the right of the main body section 12 is the
extended tunnel end 16 with the tapered poke-home connection tunnel
18.
[0048] FIG. 2 depicts an end view of a typical encapsulated high
voltage circuit board incorporating the connector contact means 10A
illustrating the external electrical connector 14 and the main body
section 12. FIG. 3 depicts a side view of a typical encapsulated
high voltage circuit board incorporating the connector contact
means 10A having the main body section 12 and the extended tunnel
end 16. FIG. 4 depicts an end view of a typical encapsulated high
voltage circuit board incorporating the connector contact means
10A; illustrating the main body section 12, the extended tunnel end
16, the tapered "poke-home" connection tunnel 18 with the thin
membrane 20 of the injection molding material 34.
[0049] FIG. 5 depicts a cross section of a typical encapsulated
high voltage circuit board incorporating the connector contact
means 10A with a conventional mold housing 22 consisting of a top
half 24 and a bottom half 26. A tapered tunnel plug 28 that creates
the tapered "poke-home connection" tunnel 18 is shown above. The
male high voltage connector 30 is shown below with a partial cross
section exposing the pointed needle contact end 32. The stipple
represents the injection molding material 34; covering the circuit
board 36, the electrical components 38, the conductive rubber slug
40 that is held in place by the metal saddle 42 and creating the
thin membrane 20 between the conductive rubber slug 40 and tapered
"poke-home connection" tunnel 18. A channel 44 cut through the
circuit board 36 fills with the injection molding material 34 to
aide in the encapsulation of the electrical components 38.
[0050] FIG. 6 depicts a perspective view of the high voltage
circuit board 36 illustrating the pre-cut slots 46, cavities 48 and
channels 44 enabling the unique installation of high voltage
components while achieving complete coverage and isolation by the
encapsulating materials 34. One high voltage axially leaded
resistor 50 is moved away from the circuit board 36 while a second
is positioned within the pre cut slot 46 with the leads 52 resting
on a segment of the printed solder circuitry 54. The conductive
rubber slug 40 with the metal saddle 42 is shown attached on the
extended end of the circuit board 56. FIG. 7 depicts a cross
section of a portion of a circuit board 36 illustrating the
location in the pre-cut slot 46 and the high voltage axially leaded
resistor 50 and the encapsulating material. FIG. 8 depicts a cross
section of a portion of a circuit board 36 illustrating the
location of high voltage electrical component 38 raised off the
board by the means of a bead of epoxy 58 and covered with the
encapsulating material 34 adjacent to one of the pre-cut channels
44 separating the electrical components 38.
[0051] FIG. 9 depicts a perspective view a typical encapsulated
high voltage circuit board incorporating the connector contact 10A
with a portion of the injection molding material 34 removed further
illustrating the number of high voltage electrical components 38
attached to the circuit board 36 and the location of the conductive
rubber slug 49 in relation to the thin membrane 20 and the tapered
poke-home connection tunnel 18. FIG. 10 depicts a perspective view
of a typical encapsulated high voltage circuit board incorporating
the connector contact 10A.
[0052] FIG. 11 depicts an alternate embodiment of the encapsulated
high voltage circuit board incorporating the connector contact 10B
with the conductive rubber slug 40, metal saddle 42 and the tapered
poke-home connection tunnel 18 on the opposite side of the circuit
board 36. With this design, the unit can be shortened and less of
the injection molding material 34 would be required.
[0053] The process of encapsulating high voltage circuitry
incorporating a connector contact means 10A and 10B shown in the
drawings and described in detail herein disclose arrangements of
elements of particular construction and configuration for
illustrating preferred embodiments of structure and method of
operation of the present invention. It is to be understood,
however, that elements of different construction and configuration
and other arrangements thereof, other than those illustrated and
described may be employed for providing this unique process in
accordance with the spirit of this invention, and such changes,
alternations and modifications as would occur to those skilled in
the art are considered to be within the scope of this invention as
broadly defined in the appended claims.
[0054] Further, the purpose of the foregoing abstract is to enable
the U.S. Patent and Trademark Office and the public generally, and
especially the scientists, engineers and practitioners in the art
who are not familiar with patent or legal terms or phraseology, to
determine quickly from a cursory inspection the nature and essence
of the technical disclosure of the application. The abstract is
neither intended to define the invention of the application, which
is measured by the claims, nor is it intended to be limiting as to
the scope of the invention in any way.
* * * * *