WO2006053386A1 - Flexible pcb thermostrip - Google Patents
Flexible pcb thermostrip Download PDFInfo
- Publication number
- WO2006053386A1 WO2006053386A1 PCT/AU2005/001750 AU2005001750W WO2006053386A1 WO 2006053386 A1 WO2006053386 A1 WO 2006053386A1 AU 2005001750 W AU2005001750 W AU 2005001750W WO 2006053386 A1 WO2006053386 A1 WO 2006053386A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- strip
- arrangement
- pads
- conductor
- connector
- Prior art date
Links
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/1927—Control of temperature characterised by the use of electric means using a plurality of sensors
- G05D23/193—Control of temperature characterised by the use of electric means using a plurality of sensors sensing the temperaure in different places in thermal relationship with one or more spaces
- G05D23/1931—Control of temperature characterised by the use of electric means using a plurality of sensors sensing the temperaure in different places in thermal relationship with one or more spaces to control the temperature of one space
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K1/00—Details of thermometers not specially adapted for particular types of thermometer
- G01K1/02—Means for indicating or recording specially adapted for thermometers
- G01K1/026—Means for indicating or recording specially adapted for thermometers arrangements for monitoring a plurality of temperatures, e.g. by multiplexing
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K1/00—Details of thermometers not specially adapted for particular types of thermometer
- G01K1/14—Supports; Fastening devices; Arrangements for mounting thermometers in particular locations
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K7/00—Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat ; Power supply therefor, e.g. using thermoelectric elements
- G01K7/16—Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat ; Power supply therefor, e.g. using thermoelectric elements using resistive elements
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
Definitions
- This invention relates to flexible printed circuit boards (PCBs), and in particular to elongated PCBs adapted to carry components at different locations.
- the invention also relates to an arrangement for connecting sensors at different locations.
- the invention also relates to an improved arrangement for applying sensors to water heater tanks. Background of the invention
- This mode of operation can result in a fairly clear temperature stratification, with a layer of hot water above a layer of cooler water.
- the temperature sensors can be associated with a controller which can be used to set the location of the thermal transition, so that the effective capacity of the tank can be adjusted to maximize efficiency for the expected average load.
- the temperature sensors may be located to detect when the thermal transition is at a selected zone, such as one quarter capacity, half capacity, three quarters capacity and full capacity, so that only the required amount of water is heated to the top of the predetermined operating temperature range, at which point the heat input can be turned off until the temperature of the water in the selected zone falls below the set minimum operating point.
- a selected zone such as one quarter capacity, half capacity, three quarters capacity and full capacity
- An embodiment of the invention provides an ambient condition sensor arrangement including one or more elongated flexible printed circuit strips to which one or more ambient condition sensing components are attached at predetermined locations.
- the or each circuit strip can have conductor tracks on a first side of the strip, and the or each sensor can be located on said first side and connected to two or more corresponding tracks.
- the conductor tracks can be formed on the flexible PCB using screen printing.
- the conductor tracks can be formed using a silver screen printing process.
- the sensors can be located at different distances along the strip.
- the sensors can be temperature sensors applied to a water heater tank
- the PCB can be a flexible ribbon cable.
- the conductor strip can be in the form of a flexible printed circuit board.
- the conductor strip can carry sets of conductor tracks for each sensor.
- the conductor strip may have a common conductor to which one terminal of two or more sensors is connected, and an individual signal line can be provided for each sensor.
- a two line bus using an appropriate communication protocol such as I 2 C, can be utilized where the electronic components include the appropriate interfaces.
- the printed circuit strip is adapted to be attached to the external surface of a water heater storage tank with a second side of the printed circuit strip opposite to the first side contacting the external surface of the tank.
- a first temperature sensor can be located to obtain a measurement of the temperature in the proximity of the top of the tank.
- Second and third sensors can be located to measure the temperature of at second and third predetermined locations.
- Reinforcing patches can be mounted on the strip to reduce stress on the components.
- Vias or plated through holes can be provided to connect a conductor on one side of the strip with a conductor on the other side of the strip.
- the sensors can be surface mounted components.
- the strip can include end-connection pads at least one end adapted for connection to a second flexible printed circuit strip.
- One strip can include first end connection pads at a first end and second end connection pads at a second end.
- the first end connection pads can be accessible for connection through the front face, and the second end connection pads are accessible for connection through the second face.
- the strip-joining contact of a first strip is on the opposite face to the mating strip-joining contacts of a second strip.
- the connector arrangements can be in the form of one or more solder pads.
- the connectors can be zero insertion force connectors.
- an intermediate connector is used to join adjacent strips.
- such a connector comprises a connector strip having strip-joining connection contacts at either end which are, in a "face down” orientation, adapted to match the strip-joining contacts of the strips being joined.
- the pads of the first connector can be on one side of the strip and the pads of the second connector can be on the other side of the strip.
- a temperature sensor arrangement for a water heater storage tank wherein the strip has a first face in contact with the tank and a second face opposite the first face on which one or more sensors are mounted.
- a water heater temperature control system including a processor control system having an input to which a flexible printed strip is connected by two or more end connector pads.
- a first strip is arranged with its component side facing away from the water heater tank, and a second strip is arranged with its component side facing the water tank, so that the strip-joining contacts face-to- face and can be joined, for example, by soldering.
- an electrical insulating layer can be inserted between the strip and the water tank.
- the sensors can be thermally insulated from the ambient atmosphere by a layer of insulation used to insulate the tank.
- the thermal insulation may be an insulation blanket, or a foam injected between the outside of the tank and the housing of the system.
- a further embodiment of the invention provides a control system including a processor control system having an input to which a flexible printed strip is connected by two or more end connector pads.
- Figure 1 shows a water heater tank to which a connector strip is attached
- Figure 2 shows the elements of a strip utilized in forming a connector strip
- Figure 3 illustrates a connector strip
- Figure 4 illustrates a component suitable for attachment with the strip of Figure
- Figure 5 A is a plan view of a connector strip
- Figure 5B is a sectional view of the strip of Figure 5 A along line A-A;
- Figure 5C is a sectional view of the strip of Figure 5A along line B-B;
- Figure 5D shows an alternative embodiment of a view similar to Figure 5C;
- Figure 6 is a plan view of a strip-joining connector
- Figure 7 is a schematic representation of a strip with thermistors attached
- Figure 8 is a representation of a further embodiment of the invention having one common conductor
- Figure 9 shows a pair of strips adapted to be connected in series
- Figure 10 shows diagrammatically details of a cross section through an assembly of components.
- the invention is described in relation to the use of two or more ambient condition sensors in the control of a water heater system, but is of more general application.
- individual temperature sensors have been inserted into the tank and connected to a relay driver circuit or the like to switch a heating element on or off.
- a particular problem which has been encountered in implementing this invention is that the length of conductor strip which is available can be less than the distance over which the sensor readings are to be taken. Accordingly, strips have been designed with strip-joining contacts or end-connection pads to enable an end of one strip to join an end of another strip or to a connector. However, the invention is also applicable to a single strip.
- a temperature sensor may be affixed to the outside of the tank and in contact with the tank.
- the use of a thin flexible PCB means that temperature sensors can be mounted on one side of the PCB and the other side can be in contact with the outside of the tank.
- the thinness of the flexible PCB permits the heat to transfer through to the temperature sensor on the other side.
- the side in contact with the tank does not carry any conductive tracks or connection points, although conductive tracks can be applied to the side in contact with the tank if they are adequately insulated.
- a number of such sensors are to be used in conjunction with a controller, they can be connected by individual wires to the controller. However, this requires a number of individual wire/component connections to be soldered.
- This invention proposes the use of a conductor strip on which two or more sensors are mounted.
- the conductor strip can be mounted on the outside of a water heater tank or other environment where it is required.
- the conductor strip forms a flexible substrate to carry the electronic components.
- Figure 1 shows a water heater tank 100 to which a connector strip 102 has been affixed.
- the strip can be affixed to the tank by adhesive, adhesive tape or other suitable means.
- the connector strip is connected at one end to a controller 106.
- Electrical components 104 may be affixed to the connector strip at intervals.
- the components in this embodiment are temperature sensors, for example, thermistors, which are two terminal devices whose resistance changes with changes in temperature.
- the sensors may only require two terminals to connect them back to the controller [061]
- the tank When the tank is in its complete form, it includes an outer jacket and the space between the outer jacket and the tank is packed with insulating material (not shown).
- the insulating material may be packed sufficiently tightly so that it holds the connector strip 102 in place. Thus the strip only needs a sufficient attachment to hold it in place while the outside jacket and insulation are installed.
- the strip can be made of a base of a flexible insulation material which can be sufficiently thin so that the heat transfers from the tank through the base material to the sensor.
- the flexibility of the strip ensures adequate contact between the strip and the tank surface for the required thermal transfer. Thus the sensors do not need to be mounted in direct contact with the tank wall.
- strips have the contact pads on one side only
- alternative strips may be mounted so that the sensors of one strip are on the opposite side to the tank wall, and on the second strip, the sensors may be in direct contact with the tank wall. This enables the contact pads of one strip to connect directly to the connector pads of the other strip.
- an additional electrical insulator can be interposed between the flexible PCB and the tank.
- Figure 2 shows the basic construction of the connector strip.
- a base insulator A base insulator
- 202 has conductive tracks 204 printed thereon.
- a plurality of conductive tracks can be formed on the insulating base 302.
- the tracks may be formed in pairs 304 where the components to be affixed are two terminal devices.
- the pairs of tracks may terminate at predetermined distances along the strip, usually with connection pads 306. Thus pair 304 terminates before pair 314, and pair 308 continues to the end of the strip.
- Components such as thermistors can be soldered to the contact pads which are located at the ends of pairs of conductors 306 and 314.
- the pair of conductors 308 can serve as strip-joining contacts for connection to another strip.
- the "upper" insulation layer 316 includes “window” cut-outs, such as 310 which correspond to pads 306 when the layer 316 is superimposed on the layer 302. This provides access to permit a sensor component to be soldered onto the pads. While individual windows are shown corresponding with each connector pad, a “double " window can be used to expose pairs of connector pads as shown at 1004 in Figure 10.
- Figure 4 shows a surface mount component 402 having solder pads 404, 406.
- pads 404, 406, and/or the pads 306 can be pre-soldered to facilitate the soldering of the component to the strip.
- Figure 5 A shows a plan view of a strip adapted at the right hand end to connect to either a device such as a controller or further strip via connector pads 508, and to connect to components via intermediate pads such as 506, and to connect to a further strip via pads 509.
- Figure 5B shows a sectional view of the strip of figure 5 A along line A-A.
- the base member 502 carries conductor 518.
- Insulation cover 514 overlies the strip 502. Holes 510, 512 are cut out of insulation cover 514 to expose the underlying pads 508, 506. These pads may be pre-soldered, as mentioned above, to facilitate the attachment of surface mounted components such as 402 in Figure 4.
- the insulation cover 514 is thin and flexible and conforms to the surface around the conductors and the surface of support base 502 as shown at 516.
- the base 502 and the conductor 518 are also thin and flexible. The thickness and other dimensions of these elements are not shown in proportion for the sake of clarity.
- the area of the pad is large in comparison with the thickness of the insulation cover 514 and permits surface mounting of components.
- Figure 5C shows a sectional view of the strip of Figure 5 A along line B-B.
- a conductor 520 runs the full length of the strip and ends in pads 508, 509 which are exposed by cut-outs in the insulation cover 514.
- Figure 5D shows an alternative arrangement to that of figure 5C, in which the strip-joining pads 508 at a first end of the strip are exposed through cut-outs in the insulation cover 514 to form "upper pads”, and the pads 509 are exposed through cut-outs in the support base 502 at the other end of the strip to form "lower pads”.
- This arrangement allows the ends of adjoining strips to be directly connected by overlaying the upper pads of one strip with the mating lower pads of the second strip. These connections can be made using surface mounting techniques.
- the connector member of figure 6 can be used.
- This connector member can be jnade of a similar structure to the strips and can have mating connector pads 602, 604 at either end connected by conductors 606 and adapted to connect to the "upper pads" of a first and a second strip.
- the number of pads and strips can be chosen as required.
- Figure 7 schematically represents a strip 700 with a pair of thermistors, 714,
- Thermistor 714 is connected via conductors 704 to pads 702.
- Thermistor 716 is connected via conductors" 708 to pads 706.
- a pair of through-conductors 712 connect a first pair of pads 710 to a second pair of pads 718.
- the pads 702, 706, 710 may be connected to a connector of a controller or to a further strip.
- the pads 718 may connect to a further thermistor on a second strip.
- the strips can be used to connect components having three or more terminals to an equal number of conductors.
- Figure 8 illustrates an embodiment of the invention in which one common conductor is used to connect to one of the terminals of the sensors.
- Figure 8 shows a sensor strip 800 having a plurality of conductors 804, 806, 810,
- Conductor 804 is a common conductor to which two or more components may be connected. Conductor 806 terminates in a connection pad 814 and common conductor 804 carries a matching pad to provide for the connection of a first component.
- Conductor 816 bends towards common conductor 804 after conductor 806 has terminated. Conductor 816 terminates in pad 820 which is spaced from a second pad on common conductor at a distance to facilitate the connection of a second component.
- Conductor 818 then bends towards common conductor 804. This may occur on the strip 802 or on a second strip 9 not shown) to which strip 802 is connected via connection pads 822.
- the further conductors 810, 812 also can be connected through to a second strip via connector pads 822. These conductors may also be bent into proximity with common conductor 804 to connect to pads at locations on the second strip where further sensors are to be attached.
- Strip 800 can be connected to the control circuitry via connection pads 824.
- one of the conductors, 804 carries a common reference potential.
- two or more sensors may connect to this single conductor 804. This can be achieved by printing the tracks to bend towards the common track after each previous track ends, as shown by tracks 814, 818. This provides the same distance between surface mount pads such as
- Figure 9 shows a pair of strips which are adapted to be connected in series.
- a first strip 900 has a plurality of conductors which terminate at a first end in an end connector 902 made up of a plurality of end connector pads.
- a common conductor 904 is formed to make a component connector 906, 908 with the adjacent conductors, each adjacent conductor terminating at its respective component connector and the common conductor 904 being stepped across to the correct component spacing at each succeeding component connector.
- the end connector 902 can be connected to a SMD connector attached to a flexible cable connected to a control board.
- the second strip 901 has a strip-joining connector 903 at a first end, which is adapted to be connected to strip-joining connector of strip 900. As described above, this may be done in a number of ways, including having connector 910 on the upper surface and connector
- FR4 laminate is suitable as the flexible PCB.
- Single sided 0.2 mm FR4 laminate provides a suitable degree of strength and flexibility.
- the conductor tracks can be covered with a layer of insulating photoresist or other polymer coating which can have apertures accurately located to expose the connection pads.
- PCB is polyamide.
- vias can be provided to connect connector pads on one side to conductor tracks on the other side of the laminate.
- additional layers of laminate can be attached opposite each component attached to the PCB to provide additional rigidity in the region of the components.
- Figure 10 shows a component 1002 connected to two conductors 1010 and 1020 through an aperture 1004 in the insulation 1022.
- the component has two solder pads 1006 and
- the first layer 1012 extends beyond the connector pads of component 1002.
- the second patch 1.014 can be somewhat snorter than the first patch, but can still extend beyond the ends of the component 1002. This arrangement thus provides a progressive stiffening of the strip in the region of the component. However, a single stiffening patch, or more than two stiffening patches can also be used. A patch having a tapered trapezium cross-section can also be used.
- the reinforcing patch may be an hollow device, rectangular, annular or other suitable shape, with sufficient stiffness and adapted to encompass the component.
- This device can be mounted on the same side as the component.
- FIG. 10 Also shown in Figure 10 is a via or through-hole 1016 which connects the conductor 1010 on the top side of the strip to the connector pad 1018 on the lower side of the strip.
- each sensor is provided with an interface chip an a protocol control chip is connected between the controller and the bus to enable each individual sensor's interface chip to communicate with the controller.
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Remote Sensing (AREA)
- Automation & Control Theory (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2005306582A AU2005306582B2 (en) | 2004-11-18 | 2005-11-17 | Flexible PCB thermostrip |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2004906608 | 2004-11-18 | ||
AU2004906608A AU2004906608A0 (en) | 2004-11-18 | Flex PCB Thermostrip |
Publications (1)
Publication Number | Publication Date |
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WO2006053386A1 true WO2006053386A1 (en) | 2006-05-26 |
Family
ID=36406771
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2005/001750 WO2006053386A1 (en) | 2004-11-18 | 2005-11-17 | Flexible pcb thermostrip |
Country Status (1)
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WO (1) | WO2006053386A1 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
ITAN20100131A1 (en) * | 2010-07-29 | 2012-01-30 | Thermowatt Spa | PERFECT ELECTRONIC AND ELECTROMECHANICAL THERMOSTAT |
US20120048259A1 (en) * | 2010-08-26 | 2012-03-01 | Wagner & Co., Solartechnik GmbH | Solar installation |
WO2012162763A1 (en) * | 2011-06-03 | 2012-12-06 | Rheem Australia Pty Limited | A water heater controller or system |
WO2012131402A3 (en) * | 2011-03-31 | 2013-06-06 | Isotera Limited | Electrical devices |
WO2015091996A1 (en) * | 2013-12-19 | 2015-06-25 | Airbus Operations (S.A.S.) | Measurement device with single control circuit |
EP2233858B2 (en) † | 2009-03-13 | 2018-06-27 | BSH Hausgeräte GmbH | Warm water reservoir with sensor system |
US10330503B2 (en) | 2013-12-19 | 2019-06-25 | Airbus Operations S.A.S. | Measurement device comprising sensors arranged in recesses covered by a single film |
US10352739B2 (en) | 2013-12-19 | 2019-07-16 | Airbus Operation S.A.S. | Simplified measurement device and method and tool for manufacturing such a device |
AU2018226481B2 (en) * | 2012-12-04 | 2020-07-23 | Oxford University Innovation Limited | Sensor, controller and system |
WO2023275557A1 (en) * | 2021-07-01 | 2023-01-05 | Mixergy Limited | Temperature sensor, heating system and controller |
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Cited By (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2233858B2 (en) † | 2009-03-13 | 2018-06-27 | BSH Hausgeräte GmbH | Warm water reservoir with sensor system |
ITAN20100131A1 (en) * | 2010-07-29 | 2012-01-30 | Thermowatt Spa | PERFECT ELECTRONIC AND ELECTROMECHANICAL THERMOSTAT |
WO2012014025A1 (en) * | 2010-07-29 | 2012-02-02 | Thermowatt S.P.A. | Improved electronic and electromechanical thermostat |
US20120048259A1 (en) * | 2010-08-26 | 2012-03-01 | Wagner & Co., Solartechnik GmbH | Solar installation |
WO2012131402A3 (en) * | 2011-03-31 | 2013-06-06 | Isotera Limited | Electrical devices |
AU2012262613B2 (en) * | 2011-06-03 | 2015-07-09 | Rheem Australia Pty Limited | A water heater controller or system |
WO2012162763A1 (en) * | 2011-06-03 | 2012-12-06 | Rheem Australia Pty Limited | A water heater controller or system |
CN103562645A (en) * | 2011-06-03 | 2014-02-05 | 瑞姆澳大利亚控股有限公司 | A water heater controller or system |
US9897334B2 (en) | 2011-06-03 | 2018-02-20 | Rheem Australia Pty Limited | Water heater controller or system |
US11733106B2 (en) | 2012-12-04 | 2023-08-22 | Oxford University Innovation Limited | Sensor, controller and system |
AU2018226481B2 (en) * | 2012-12-04 | 2020-07-23 | Oxford University Innovation Limited | Sensor, controller and system |
CN105829835A (en) * | 2013-12-19 | 2016-08-03 | 空中客车运营简化股份公司 | Measurement Device With Single Control Circuit |
US10136531B2 (en) | 2013-12-19 | 2018-11-20 | Airbus Operations S.A.S. | Measurement device with single control circuit |
US10330503B2 (en) | 2013-12-19 | 2019-06-25 | Airbus Operations S.A.S. | Measurement device comprising sensors arranged in recesses covered by a single film |
US10352739B2 (en) | 2013-12-19 | 2019-07-16 | Airbus Operation S.A.S. | Simplified measurement device and method and tool for manufacturing such a device |
WO2015091996A1 (en) * | 2013-12-19 | 2015-06-25 | Airbus Operations (S.A.S.) | Measurement device with single control circuit |
FR3015664A1 (en) * | 2013-12-19 | 2015-06-26 | Airbus Operations Sas | MEASURING DEVICE WITH SINGLE CONTROL CIRCUIT |
WO2023275557A1 (en) * | 2021-07-01 | 2023-01-05 | Mixergy Limited | Temperature sensor, heating system and controller |
GB2611277A (en) * | 2021-07-01 | 2023-04-05 | Mixergy Ltd | Temperature sensor |
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