BACKGROUND OF THE INVENTION
Field of the Invention:
[0001] This invention is directed generally to terminal modules for housing small circuits
which are electrically connected across field wiring terminals and, more particularly,
to modularized packages which are adapted for concurrent physical and electrical connection
to two or more terminals on a frame containing a plurality of field wiring terminals.
A primary application of the invention is in electrical data acquisition systems using
microprocessors and other monitoring circuitry mounted on printed circuit boards
to manage data input and output, such as for providing control and protection functions
for systems in electrical power plants and generators.
Prior Art:
[0002] Present day industrial electrical data acquisition and processing systems frequently
require stacked termination-frame-assemblies or terminal connectors mounted typically
in a cabinet with the field terminals accessible through a first door and with the
circuit boards and component assemblies which are connected to other equipment in
the cabinet being accessible through an opposite door. In such applications it is
frequently required to have one or more electronic components mounted across the field
wiring leads, i.e., not part of the circuit board assemblies and separately accessible.
While such components could be made a part of the I/O electrical circuitry itself,
frequently this is not possible or convenient. Thus, often it is desirable that the
circuit boards to which the field terminals connect may be removed for maintenance
without affecting the overall field system operation, which can be done if the components
in question are separately connected to the field terminals. For example, one or more
dropping resistors may be utilized in a field current loop, the dropping resistors
being connected across the field terminals while the processing and analyzing circuitry
receives its input from the dropping resistors.
[0003] A common prior practice in applications as referred to above is to physically terminate
the wire leads of the electronic components directly to the screw terminals used
for the field wiring. This arrangement not only gives the appearance of a last minute
design change, but exposes the electronic component or components to physical damage
during assembly, maintenance or other events. The performance and maintenance of the
external components is sensitive to unforeseen installation mistakes, such as shorting
of the component to the chassis where the proper assembly technique is not followed.
Further, it is readily seen that where plural components are to be connected across
two or more field terminals, the method of direct attachment of the components to
the terminals becomes even less desirable.
[0004] A typical prior art approach has been to contain an external component in a potted
box or other potting means, with metal connector blades or pins extending out of the
potting material. Basically this constitutes simply an encapsulation of the component
in order to protect it, and does not provide the desired ability to achieve reliable
electrical and mechanical attachment.
[0005] There is thus a need for a standardized package and means of reliably connecting,
both mechanically and electrically, external components to field screw terminals.
This need has required an engineered packaging approach that permits housing of a
plurality of small electronic components in a small, modular, lightweight and, rugged
assembly, and which provides reliable and quick attachment of the component module
to the terminal assembly.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, there is provided a terminal module for
attaching to a plurality of terminals, of a terminal assembly, in use, comprising
a printed circuit board having a plurality of extending conductive blades for physical
and electrical connection to respective ones of said terminals characterized by, a
potted component enclosure housing at least a portion of said printed circuit board
for enclosing an electronic component mounted on said printed circuit board, said
conductive blades protruding from said potted component means, electrical conductor
means on said printed circuit board for defining a plurality of circuit points of
said electronic component means and for making electrical connections between respective
ones of said circuit points and respective ones of said blades, whereby when said
blades are connected to said terminals, said circuit points are in electrical connection
with said terminals.
[0007] Described herein is a preferred form of a terminal module which is a compact assembly
of predetermined geometry which is attached to two or more terminals of a terminal
block connector. The module comprises a printed circuit board having a first portion
which carries one or more circuit components and which is potted within a rectangular
plastic shell. The remainder of the integral printed circuit board protrudes from
the shell and has blade portions configured for use both as electrical terminals and
for physical attachment to the screw terminals of the terminal connector. The module
thus provides the advantages of a standardized package which is adapted to carry a
plurality of components and for making reliable mechanical and electrical connection
to the field terminals.
[0008] The printed circuit board assembly as described herein can be used for reliable and
efficient mounting of components, the module further providing efficient means for
attaching the entire assembly to the field terminals. In a preferred form of the invention
a flame-retardant potting shell is utilized along with an encapsulating material which
reduces risk of flammability. A resilient high-temperature pre-coating is placed over
the electronic components prior to the encapsulation to prevent breakage by stresses
set up when the encapsulant is curing.
[0009] Further advantages of the terminal module of the invention are provided to enhance
the reliability of proper installation and to insure long term reliable use. The printed
circuit is provided with plate-through holes and a double sided circuit pattern for
connecting the components, thereby providing redundant paths on each side of the board
and better connection at the terminal. The invention further employs necked-down etched
circuitry to increase the creep distance between the board circuit conductors at the
point of entry into the encapsulant. The shell housing the component assembly is preferably
a rectangular shell which carries identifying markings and date codes. A polarity
mark is etched into the board circuitry to verify correct assembly and installation
of polarity sensitive circuitry on the screw terminals.
[0010] While the preferred embodiment is described as providing for connection of the module
to two adjacent terminals on a terminal block, the modular design of this invention
provides for and embraces ready extension to applications requiring connection to
more than two terminals and/or non-adjacent terminals. Whatever the required field
terminal arrangement, the use of the integral printed circuit board enables any desired
combination of components to be reliably connected to a terminal block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A more detailed understanding of the invention may be had from the following description
of a preferred embodiment, given by way of example only, and to be understood in
conjunction with the accompanying drawings in which:
Figure 1 is a front elevation view of a prior art termination frame of the form which
may be utilized with the terminal module of this invention.
Fig. 2A is a side elevation view of the terminal module of this invention connected
to a terminal strip of a termination frame, and illustrating the positioning of the
potted portion of the module between adjacent stacked terminal strips.
Fig. 2B is a front elevation view of the terminal module connected to two adjacent
screw terminals of a termination frame.
Figs. 3A, B, and C are diagrammatic front, side and back views of a terminal module
of this invention.
Figs. 4A and B are diagrammatic representations of the component side and back respectively
of the printed circuit board, showing the redundant conductor path arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The terminal module disclosed in this specification is used in conjunction with
a terminal block connector which provides connections through to one or more printed
circuit boards, such as is disclosed, for example, in U.S. Patent 4,542,443, Rinefierd,
Jr., assigned to the same assignee. The Rinefierd patent discloses what is referred
to therein as a termination frame assembly, and more particularly a stack of termination
frame assemblies mounted in a cabinet. Figure 1 represents substantially the same
drawing as presented in Fig. 3 of U.S. Patent 4,542,443, and shows a termination frame
assembly, referred to herein as a termination frame 40 having thereon two terminal
strips 45, each strip 45 having a plurality of screw-type terminals 47 aligned in
a horizontal array. As seen more particularly in Fig. 2B, a terminal module unit 50
is attached to a pair of adjacent terminals 47 of the strip 45. Although just one
such terminal module 50 is illustrated as being so connected, it is to be understood
that any appropriate number of such modules may be connected to terminals 47. Furthermore,
it is within the scope of the invention that the modules be connected to two or more
terminals 47, which terminals may be adjacent or non-adjacent depending upon the application
involved. Reference may be made to the aforementioned U.S. Patent 4,542,443 for a
discussion of the manner and means by which printed circuit boards, including microprocessors,
are mounted to the other side of termination frame 40 and in electrical connection
with terminals 47 for managing data input and output, and the manner by which wiring
from field locations is connected through to the termination frame 40.
[0013] Referring particularly to Figs. 2A and 2B, there is illustrated a module 50 mounted
in mechanical and electrical connection with a pair of adjacent terminals 47. A field
wire 48 and wiring lug 49 are shown connected to a terminal 47. The module comprises
a one-piece integral circuit board 51 which, as illustrated, has two upper portions
or blades 58, 59 which are physically separated by a slot 60. The blades have holes
64 (see also Fig. 3A) in the upper portions thereof of a size and spacing to enable
mounting of the module onto terminals 47 and mechanical connection thereto. The lower
portion of the printed circuit board, as seen in Fig. 2A, carries one or more electrical
components electrically wired thereto and shown symbolically at 56. The lower portion
carrying the component assembly is housed within a substantially rectangular plastic
shell 52, the component assembly being contained within encapsulant 53. Although
components are illustrated as being on only one side of the board 51, they may be
contained on either or both sides. The potted assembly comprising elements 52, 53,
56 and the lower portion of the board 51 is referred to as the potted component means
54.
[0014] In the preferred embodiment, the shell 52 is a flame retardant material such as diallyl
phthalate, while the encapsulating material may be a two part epoxy comprising an
epoxy casting resin and a catalyst. The resin is mixed in a container until uniform
in texture, at which time 8-9% by weight of the catalyst is blended thoroughly therein.
The mixture is then poured into the potting shell 52 to the indicated level. Also,
in the preferred embodiment, a resilient high temperature pre-coating of an RTV silicone
is utilized for pre-coating the electronic components, so as to prevent breakage,
e.g., of glass diode packages by stresses set up by the encapsulant when curing.
[0015] As seen further in Fig. 2A, a plurality of terminal strips 45 may be stacked one
on top of another, leaving a gap therebetween. The terminal module is designed so
that the shell 52 fits just below the forwardly extending portion of the terminal
strip and between vertically aligned adjacent terminal strips.
[0016] Referring to Figs. 3A-3C, the terminal module unit 50 is illustrated diagrammatically
in front, side and rear views. Each of the blades 58, 59 of the block has a conductive
surface which is preferably a copper coating covered with tin plating. This surface
is neck-down etched as shown at 66 to increase the creep distance between the circuit
conductors at the point of their entry into the encapsulant 53. By this means the
rugged structural support of the glass-epoxy printed circuit board substrate and the
terminal conductors are maintained, without any sacrifice of the electrical characteristics.
The use of the printed circuit terminal conductor surfaces, or tabs, avoids fractures
usually associated with work-hardening of tabs comprised of all copper which may occur
under continuous vibration conditions at the stress concentration point.
[0017] As illustrated in Fig. 3C, the rectangular shell is adapted for carrying identifying
markings and/or date codes, which provides an important advantage for field installations
of this nature. Further, as indicated at 75, a polarity mark is etched into the circuitry
on one of the blades to verify the correct assembly and installation of polarity sensitive
circuitry on the screw terminals. Further, different colored potting shells are used
for each unique function or component assembly, to make assembly inspection and maintenance
for the system easier, simpler and more reliable.
[0018] Referring to Figs. 4A and 4B, there are shown diagrammatic views of opposite sides
of a printed circuit board carrying a component assembly comprising a capacitor C1
in parallel with a series combination of diodes D1, D2 and D3. As illustrated, each
of the main terminal tabs, or conductive pathways 72, 73 is printed on each side of
the respective blades 58, 59. In other words, the circuit conductive material on the
printed circuit board is double-side-printed with plated-through holes 76 connecting
the opposite sides. In this matter redundant paths are provided on each side of each
blade, thereby providing improved reliability over the technique of depending merely
on one soldered connection for each component lead. The double sided printed blade
also insures excellent connection at the point of the electrical contact with the
screw terminal 47.
[0019] There has thus been disclosed an improved terminal module for carrying one or more
circuit components for connection to field terminals, in combination with one or more
terminal block connectors. The single integral printed circuit board which performs
the dual functions of carrying a circuit component assembly in predetermined wired
form as well as, of providing reliable means for electrical and mechanical connection
to the field terminals, provides distinct advantages over the prior art. The module
provides simple but reliable packaging of components in standardized packages, thereby
simplifying installation in the field.
1. A terminal module (50) for attaching to a plurality of terminals (47), of a terminal
assembly, in use, comprising:
a printed circuit board (51) having a plurality of extending conductive blades
(58) for physical and electrical connection to respective ones of said terminals characterized
by,
a potted component enclosure (54) housing at least a portion of said printed
circuit board for enclosing an electronic component mounted on said printed circuit
board, said conductive blades protruding from said potted component means,
electrical conductor means (78) on said printed circuit board for defining a
plurality of circuit points (76) of said electronic component means and for making
electrical connections between respective ones of said circuit points and respective
ones of said blades (58), whereby when said blades are connected to said terminals,
said circuit points are in electrical connection with said terminals.
2. The module as in claim 1, wherein said circuit board includes double sided printed
circuit material thereon with plated-through holes therethrough, thereby providing
redundant conductor paths on each side of each said blade.
3. The module as described in claim 1, wherein said potted component enclosure comprises
a plurality of components electrically connected to said board.
4. The module as described in claim 3, wherein said potted component enclosure comprises
a potting shell (52) for enclosing said components and an encapsulating material within
said shell and encapsulating said components.
5. The module as described in claim 4, wherein said potting shell is composed of a
flame-retardant material and filled with a flame-retardant encapsulant.
6. The terminal module as described in claim 1 wherein a polarity mark is etched into
one of said blades to facilitate correct assembly and installation.
7. The module as described in claim 1, wherein each of said blades has a predetermined
similar geometry, and said blades are spaced one from another corresponding to a required
terminal spacing.
8. The module as described in claim 7, wherein said potted component enclosure comprises
a housing which encloses the lower portion of said board on both sides thereof, and
wherein said blades extend from said housing.
9. The module as described in claim 8, wherein said blades comprise etched conductor
circuitry on each side thereof, said circuitry being necked-down at the point of entry
into said potted component means, thereby to increase the creep distance between said
blade conductor surfaces.