Flexible printed circuit board having a battery mounted thereon

Abstract

A flexible printed circuit board (PCB) can have one or more button cell batteries mounted thereto such that the flexibility of the flexible PCB is maintained. The flexible PCB has one or more battery contact pads fabricated thereon. Each battery contact pad includes a pattern of metallized vias, each via extending from a top surface to a bottom surface of the flexible PCB. A button cell battery can be positioned above or below the battery contact pad. A conductive light-cured epoxy is applied to and into each metallized via to contact and adhere to the button cell battery, thereby forming a conductive path from the battery through the battery contact pad to a printed conductor on the flexible PCB. Methods of mounting one or more button cell batteries to a flexible PCB, among other aspects, are also provided.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 989,587, filed March 13, 2020, the disclosure of which is incorporated herein by reference in its entirety for all purposes. Technical Field

[0003] The present invention relates generally to battery-powered devices, and more specifically to battery-powered devices having a flexible printed circuit board (PCB). Background Technology

[0004] Flexible PCBs are assemblies of electronic circuits and components manufactured on flexible substrates. Compared to rigid PCBs, flexible PCBs offer many advantages, including the ability to conform to desired shapes (e.g., bending). Many small, battery-powered electronic devices can benefit from flexible PCBs. However, one or more batteries and their holders in such devices are often the thickest parts of the electronic components on the PCB, thus increasing the PCB's rigidity and defeating the purpose of a flexible PCB. Therefore, there is a need to provide battery power to small, battery-powered electronic devices with flexible PCBs without adversely affecting the flexibility of the PCB. Summary of the Invention

[0005] According to one aspect, a flexible printed circuit board (PCB) is provided, comprising: a metallized via extending from a first surface of the flexible PCB to an opposing second surface; a battery contacting and covering the metallized via; and a conductive photocurable epoxy resin disposed on the second surface above and within the metallized via, such that the conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the metallized via.

[0006] According to another aspect, a flexible PCB is provided, comprising a first segment and a second segment, wherein the first segment is separated from the second segment by a slit extending from a top surface to a bottom surface through the flexible PCB. The flexible PCB further includes a first metallized via and a second metallized via, wherein the first metallized via extends from the top surface to the bottom surface through the flexible PCB in the first segment, and the second metallized via extends from the top surface to the bottom surface through the flexible PCB in the second segment. The flexible PCB also includes a battery inserted into the slit such that the battery contacts the bottom surface of the first segment below the first metallized via and contacts the top surface of the second segment above the second metallized via. The flexible PCB further includes a first conductive photocurable epoxy resin and a second conductive photocurable epoxy resin. The first conductive photocurable epoxy resin is disposed on the top surface of the first segment above and within the first metallized via, such that the first conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the first metallized via. Furthermore, the second conductive photocurable epoxy resin is disposed above and in the second metallized via on the bottom surface of the second segment, such that the second conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the second metallized via.

[0007] According to another aspect, a flexible PCB is provided, comprising: a first metallized via extending from a top surface to a bottom surface of the flexible PCB; a battery positioned above the first metallized via on the top surface; a first conductive photocurable epoxy resin disposed on the bottom surface of the flexible PCB above and within the first metallized via, such that the first conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the first metallized via; an arm having a second metallized via extending from a top surface to a bottom surface of the arm through the arm, the arm being positioned on the battery such that the bottom surface of the arm contacts the battery and the second metallized via is above the battery; and a second conductive photocurable epoxy resin disposed on the top surface of the arm above and within the second metallized via, such that the second conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the second metallized via.

[0008] Other aspects, features, and advantages of this disclosure may be apparent from the following detailed description and illustration of several exemplary embodiments and implementations, including the preferred mode contemplated for carrying out the invention. This disclosure is also capable of other and different embodiments, and several details thereof may be modified in various aspects, all without departing from the scope of the invention. This disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the appended claims (see further below). Attached Figure Description

[0009] The accompanying drawings described below are for illustrative purposes and are not necessarily drawn to scale. Therefore, the drawings and descriptions are to be considered illustrative in nature and not restrictive. The drawings are not intended to limit the scope of the invention in any way.

[0010] Figure 1A A plan view of a portion of a flexible printed circuit board (PCB) having a battery contact pad formed thereon, according to an embodiment, is shown.

[0011] Figure 1B It shows along Figure 1A The section line 1B-1B is cut off Figure 1A A cross-sectional side view of a portion of a flexible PCB.

[0012] Figure 2 A cross-sectional side view of another portion of a flexible PCB having a button battery mounted and electrically connected thereto, according to an embodiment, is shown.

[0013] Figure 3 A flowchart illustrating a method for mounting a button cell battery onto a flexible PCB according to an embodiment is shown.

[0014] Figure 4A and 4B A plan view of another portion of a flexible PCB according to an embodiment is shown, the other portion having a plurality of slits or cutouts arranged therein to accommodate mounting and electrically connecting one or more batteries to the flexible PCB.

[0015] Figure 5 A flowchart of another method for mounting a button battery to a flexible PCB according to an embodiment is shown.

[0016] Figure 6A A plan view of a flexible PCB with a foldable arm extending therefrom, according to an embodiment, is shown.

[0017] Figure 6B and 6C The embodiments are shown respectively. Figure 6A Plan view and side view of a flexible PCB, wherein a foldable arm folds to mount and electrically connect a pair of button batteries to the flexible PCB.

[0018] Figure 7 A plan view of a flexible PCB material configured to manufacture flexible PCBs with foldable arms, according to an embodiment, is shown.

[0019] Figure 8 The illustration shows a plan view of a flexible PCB according to an embodiment, the flexible PCB having attachable arms for mounting and electrically connecting a pair of button batteries to the flexible PCB.

[0020] Figure 9 An example is shown. Figure 8 Plan view of the attachable arm.

[0021] Figure 10 A flowchart of another method for mounting a button battery to a flexible PCB according to an embodiment is shown.

[0022] Figure 11 A plan view of a flexible PCB with a battery contact pad according to an embodiment is shown.

[0023] Figure 12 A simplified plan view block diagram of a continuous glucose monitor (CGM) wireless transmitter with a flexible PCB according to an embodiment is shown. Detailed Implementation

[0024] For example, a flexible printed circuit board (PCB) can include an assembly of electronic circuits and / or components surface-mounted on a flexible plastic substrate. The flexible plastic substrate can be, for example, polyimide, polyetheretherketone (PEEK), conductive transparent polyester film, etc. Flexible PCBs are typically very thin, usually no more than a few millimeters thick. Flexible PCBs can advantageously bend or flex during their use. In contrast, rigid PCBs, which are thicker than flexible PCBs, may be damaged and / or the circuitry imprinted on them may malfunction if bent or flexed during use.

[0025] One type of small, battery-powered electronic device that can benefit from a flexible PCB is the continuous glucose monitor (CGM) wireless transmitter. A CGM wireless transmitter can be placed on the user's body to automatically measure glucose periodically and wirelessly transmit those measurements to a receiver and / or insulin pump. A CGM wireless transmitter with a flexible PCB for the sensor and transmitter circuitry allows it to conform to the surface of the user's body at the attachment point, thus improving adhesion and / or user comfort when wearing the CGM. CGMs are typically powered by button batteries, such as micro silver oxide batteries. However, holding button batteries in conventional button battery holders, which are usually configured to be mounted to a rigid PCB, does not achieve the benefits of a flexible PCB because the thickness and size of the battery holder increase the rigidity of the flexible PCB.

[0026] According to the embodiments disclosed herein, button batteries (and batteries with similar configurations) can be directly mounted onto a flexible PCB without using a conventional battery holder. This direct mounting maintains the overall flexibility of the flexible PCB by minimizing the additional thickness added to the PCB by the button batteries. For example, in one embodiment, the maximum thickness of the flexible PCB on which one or more button batteries are directly mounted may be only about 1.6 mm, thus allowing the CGM wireless transmitter with the flexible PCB to easily conform to the surface of the user's body at the attachment point.

[0027] To ensure a reliable mechanical and electrical connection between the battery and the flexible PCB, battery contact pads formed on the flexible PCB and methods for connecting the battery to the flexible PCB are provided according to one or more embodiments, as will be described below. Figure 1A-12 To explain in more detail.

[0028] Figure 1A and 1B A portion 100 of a flexible PCB 102 having a battery contact pad 104 formed thereon is shown according to one or more embodiments. The battery contact pad 104 includes a plurality of metallized through-holes 106 arranged in a pattern. Figure 1A(Only a few are marked in the diagram). Other suitable patterns besides those shown can be used. Each metallized via 106 is a through-hole extending from a first surface 108 of the flexible PCB 102 to an opposing second surface 110. A conductive metal 111, such as copper, can be disposed above and over the inner surface of each metallized via 106. Other suitable conductive metals can be used. Printed conductors 112a formed on the first surface 108 surround and electrically connect the plurality of metallized vias 106 to each other, and printed conductors 112b formed on the second surface 110 also surround and electrically connect the plurality of metallized vias 106 to each other. Thus, the plurality of metallized vias 106 electrically connect the printed conductors 112a and 112b to each other. The printed conductors 112a and 112b can be copper or any other electrical conductor suitable for printing on a flexible PCB. In some embodiments, each metallized via 106 can have a diameter in the range of 0.5 mm to 2 mm, and the battery contact pad 104 can have a diameter in the range of 3 mm to 15 mm.

[0029] Figure 2 A portion 200 of a flexible PCB 202 according to one or more embodiments is shown, the portion having a battery 214 attached to a battery contact pad 204 on a bottom surface 210 of the flexible PCB 202. The battery contact pad 204 may be similar to or identical to a battery contact pad 104. The battery 214 may be a button cell battery, and more specifically, a micro silver oxide battery. Alternatively, the battery 214 may be of another type having a similar configuration (e.g., having a flat surface). A conductive photocurable epoxy resin, such as a conductive UV-curable epoxy resin 216, is disposed on the top surface 208 in each metallized via 206. Figure 2 The conductive UV-curable epoxy resin 216 is positioned above and in the middle (only three are marked in the image), allowing it to contact and adhere to the battery 214 and provide a conductive path from the battery 214 through the metallized via 206 to the printed conductor 212a (and in some embodiments, to the printed conductor 212b on the bottom surface 210). The printed conductor 212a can be connected to other circuitry, components, or connectors (not shown) on the flexible PCB 202. The conductive UV-curable epoxy resin 216 can be, for example, Panacol-Elosol GmbH. 3063, 3064, or 3065. Advantageously, battery 214 is directly mounted to flexible PCB 202 without a battery holder.

[0030] Figure 3 A method 300 for mounting a battery to a flexible PCB according to one or more embodiments is illustrated. At process block 302, method 300 may include positioning a battery contact pad of the flexible PCB onto the surface of the battery. Figure 2As shown, for example, the battery contact pad 204 of the flexible PCB 202 can be positioned on the top surface of the button battery 214.

[0031] At process block 304, method 300 may include applying a conductive UV-curable epoxy resin to a battery contact pad such that the epoxy resin fills the metallized vias of the battery contact pad and contacts the battery surface. The conductive UV-curable epoxy resin is used as an adhesive and / or “cold” solder for surface mounting of components (particularly heat-sensitive components) to a flexible PCB. The conductive UV-curable epoxy resin may be applied in any suitable manner and should at least substantially fill sufficient metallized vias such that a sufficient amount contacts the battery surface to establish a reliable mechanical and electrical connection between the battery and the metallized vias. See again Figure 2 The conductive ultraviolet-cured epoxy resin 216 preferably completely fills each metallized through hole 206 and fully contacts the top surface of the battery 214.

[0032] At process block 306, method 300 may include exposing the battery contact pad to ultraviolet light to cure a conductive ultraviolet-cured epoxy resin. Figure 2 As shown, the conductive UV-curable epoxy resin 216 covering the battery contact pad 204 can be exposed to UV light 218 to cure the conductive UV-curable epoxy resin 216, thereby establishing a reliable mechanical and electrical connection between the battery 214 and the metallized via 206. Depending on the power of the UV light, the type of epoxy resin, and the ambient temperature, the curing time may range from a few seconds to about one minute. Once cured, a robust conductive junction is formed between the battery and the battery contact pad.

[0033] It is worth noting that the pattern of metallized vias on the battery contact pads advantageously promotes the curing of the conductive UV-curable epoxy resin, resulting in virtually no uncured epoxy. Uncured epoxy can weaken or even prevent the formation of reliable mechanical and electrical connections. The pattern of metallized vias increases the conductive area, thereby reducing the overall connection resistance, and the relatively large vias allow UV light to reach the bottom of the epoxy resin in each via (i.e., at the battery surface), thus improving curing.

[0034] In order to complete Figure 2 The electrical connection of the battery 214 shown (where only one terminal, for example, the negative terminal, is shown as connected) requires a second connection to another terminal (for example, the positive terminal) on the bottom surface of the battery 214. Figure 4A , 4B Figures 6A-6C and 8 illustrate several embodiments in which a second connection to the battery can be made while advantageously maintaining the overall flexibility of the flexible PCB.

[0035] Figure 4A and 4BA portion 400 of a flexible PCB 402 according to one or more embodiments is shown, the portion having battery contact pads 404a-404d and a plurality of slits or cutouts 420a, 420b, and 420c arranged in the flexible PCB 402 to accommodate one or more button batteries 414a and 414b (or batteries with similar configurations) mounted to the flexible PCB 402 at the battery contact pads 404a-404d. Each of the battery contact pads 404a-404d may be similar to or identical to battery contact pad 104. The slits 420a-420c all extend from the top surface 408 to the bottom surface of the flexible PCB 402. Figure 4A and 4B (Not shown in the image). Slits 420a-420c can be made in any suitable manner. Slits 420a and 420b form a first segment 422 including battery contact pads 404a and 404b, and slits 420b and 420c form a second segment 424 including battery contact pads 404c and 404d. The first segment 422 is separated from the second segment 424 by slit 420b.

[0036] like Figure 4B As shown, battery 414a can be inserted into slit 420b and through slit 420a such that one surface of battery 414a (e.g., the negative terminal surface shown) contacts the bottom surface of the first segment 422 below battery contact pad 404a (and its metallized via) and the opposite surface (e.g., the positive terminal surface) contacts the top surface 408 of the second segment 424 above battery contact pad 404c (and its metallized via). Similarly, battery 414b can be inserted into slit 420b and through slit 420a such that one surface of battery 414a (e.g., the positive terminal surface shown) contacts the bottom surface of the first segment 422 below battery contact pad 404a (and its metallized via) and the opposite surface (e.g., the negative terminal surface) contacts the top surface 408 of the second segment 424 above battery contact pad 404c (and its metallized via).

[0037] To form a mechanical and electrical connection between batteries 414a and 414b and battery contact pads 404a-404d, conductive UV-curable epoxy resin can be disposed above and within each of the plurality of metallized vias in the battery contact pads 404a-404d, such that the conductive UV-curable epoxy resin contacts and adheres to each battery 414a and 414b after UV curing and provides a conductive path from each battery 414a and 414b to its corresponding pair of battery contact pads 404a-404d (and the plurality of metallized vias), as shown in example... Figure 2 Similar to what is shown in the middle and combined with the following: Figure 5 As stated above.

[0038] It should be noted that in some embodiments, depending on the configuration of the circuitry and / or components (not shown) imprinted and / or mounted on the flexible PCB 402, the batteries 414a and 414b can be coupled with... Figure 4B The reverse of the method shown is used instead of inserting the second segment 424 below to contact the battery contact pads 404a-404d.

[0039] It should also be noted that the printed conductors (not shown) can electrically connect the battery contact pads 404a-404d to other circuits and / or components embossed and / or mounted on the flexible PCB 402.

[0040] It should be further noted that although two batteries 414a and 414b are shown, in other embodiments, portions 400 and slits 420a-420c may be configured to accommodate only a single button cell, depending on the power requirements of the circuitry and / or components embossed and / or mounted on the flexible PCB 402.

[0041] Figure 5 A method 500 is illustrated for mounting a button cell battery (or a battery with a similar configuration) to a flexible PCB having a plurality of slits for receiving the battery, according to one or more embodiments. At process block 502, method 500 may include providing a flexible PCB having at least two battery contact pads and a plurality of slits arranged to receive at least one battery. For example, as Figure 4A As shown, the flexible PCB 402 may be provided with battery contact pads 404a-404d and a plurality of slits 420a, 420b and 420c arranged to accommodate one or more button batteries 414a and / or 414b.

[0042] At process block 504, method 500 may include inserting a battery into one or more slits such that the battery contacts a battery contact pad on one surface of the battery and another battery contact pad on an opposite surface of the battery. For example, as Figure 4B As shown, battery 414a can be inserted into slit 420b and through slit 420a such that one surface of battery 414a (e.g., the negative terminal surface shown) contacts battery contact pad 404a (and its metallized through-hole) and the opposite surface of battery 414a (e.g., the positive terminal surface) contacts battery contact pad 404c (and its metallized through-hole).

[0043] At process block 506, method 500 may include applying a conductive, UV-curable epoxy resin to the accessible side of each contact pad, such that the epoxy resin fills the metallized vias of each contact pad and contacts the battery surface. For example, refer to Figure 2 , 4AIn addition to 4B, a first conductive UV-curable epoxy resin (e.g., conductive UV-curable epoxy resin 216) can be applied on the top surface 408 of the first segment 422 above and within the battery contact pad 404a (and its metallized via), such that the first conductive UV-curable epoxy resin contacts the negative terminal surface of the battery 414a. Furthermore, a second conductive UV-curable epoxy resin (e.g., conductive UV-curable epoxy resin 216) can be applied on the bottom surface of the second segment 424 (…). Figure 4B The second conductive UV-cured epoxy resin is applied above and within the battery contact pad 404c (and its metallized through-hole) to contact the positive terminal surface of the battery 414a (not shown in the image). Figure 4B (Not shown in the image).

[0044] At process block 508, method 500 may include exposing each battery contact pad to ultraviolet light to cure a conductive ultraviolet-cured epoxy resin. (Reference) Figure 4B Continuing with the example above, the first conductive UV-cured epoxy resin above and within the battery contact pad 404a can be exposed to ultraviolet light (e.g., Figure 2 The first conductive UV-cured epoxy resin is cured by UV light (218), thereby establishing a reliable mechanical connection between the negative terminal surface of battery 414a and battery contact pad 404a (i.e., the cured epoxy resin adheres to the battery surface and the metallized via). A conductive path is also established from the negative terminal surface of battery 414a to and through battery contact pad 404a (through its metallized via). Similarly, a second conductive UV-cured epoxy resin above and within battery contact pad 404c can be exposed to UV light (e.g., UV light 218). Figure 2 Ultraviolet light (218) is used to cure a second conductive ultraviolet-cured epoxy resin, thereby establishing a reliable mechanical connection between the positive terminal surface of the battery 414a and the battery contact pad 404c. A conductive path is also established from the positive terminal surface of the battery 414a to and through the battery contact pad 404c (through its metallized through-hole). It should be noted that the first and second conductive ultraviolet-cured epoxy resins may be exposed to ultraviolet light sequentially or simultaneously (e.g., by one ultraviolet illumination device pointing to the top surface 408 and another ultraviolet illumination device pointing to the bottom surface (not shown) of the flexible PCB 402).

[0045] Figures 6A-6C A flexible PCB configuration 600 with a foldable arm 626, according to one or more embodiments, is shown. The foldable arm is configured to mount and electrically connect a pair of button batteries 614a and 614b (or batteries with a similar configuration) to a flexible PCB 602. Figure 6AAs shown, the flexible PCB 602 initially has a folding arm 626 extending therefrom. The folding arm 626 may have battery contact pads 604a and 604b formed therein, which are connected to each other via a printed conductor 612a on one surface of the folding arm 626 and, in some embodiments, via printed conductors 612b on opposite surfaces of the folding arm 626 (see [link to documentation]). Figure 6B Each of the battery contact pads 604a and 604b may be similar to or identical to battery contact pad 104. The flexible PCB 602 may have one or more button batteries 614a and 614b, which are placed on the top surface 608 of the flexible PCB 602 on corresponding battery contact pads 604c and 604d formed in the flexible PCB 602 (see...). Figure 6C Above. Each of the battery contact pads 604c and 604d may also be similar to or the same as the battery contact pad 104. In those embodiments where only a single battery is required, both the foldable arm 626 and the flexible PCB 602 may have only one properly positioned battery contact pad, and the length of the foldable arm 626 may be adjusted accordingly.

[0046] In embodiments where the area requiring mounting one or more batteries needs a certain degree of rigidity to facilitate the assembly process of the flexible PCB 602, a non-conductive battery reinforcement 628 can be used to hold batteries 614a and 614b. The battery reinforcement 628 can have a height or thickness no greater than that of batteries 614a and 614b. Any suitable non-conductive material (e.g., rigid plastic) can be used to manufacture the battery reinforcement 628. The battery reinforcement 628 can advantageously provide rigidity to the battery mounting area without increasing the height of the PCB assembly of the batteries, circuitry, and / or components. The flexibility of the remaining portion of the flexible PCB 602 is not adversely affected by the battery reinforcement 628.

[0047] Figure 6B and 6C A flexible PCB 602 is shown with a foldable arm 626 folded over and over batteries 614a and 614b. In some embodiments, the radius R of the fold at the fold of the foldable arm 626 can be about 1.5 mm (+ / - 0.1 mm). The foldable arm 626 is configured to fold onto only one surface of the flexible PCB 602 (e.g., folding onto the top surface 608, as shown). That is, the foldable arm 626 is fabricated with pre-cuts to fold onto either the top or bottom surface of the flexible PCB 602, but not onto both simultaneously. The foldable arm 626 can be combined with the above. Figure 2 , 3The same or similar manner described in 4B and 5 is used to mechanically and electrically connect the batteries 614a and 614b to the batteries by applying and curing conductive UV-cured epoxy resin 616 disposed above and within each of the battery contact pads 604a and 604b from the top surface of the foldable arm 626 (as described in 4B and 5). Figure 6C (As shown in the diagram). Similarly, batteries 614a and 614b can be combined with the above. Figure 2 , 3 The same or similar methods described in 4B and 5 are used to mechanically and electrically connect the conductive UV-curable epoxy resin 616 disposed above and in each of the battery contact pads 604c and 604d to the top surface 608 of the flexible PCB 602 by applying and curing it from the bottom surface 610 of the flexible PCB 602. It should be noted that the conductive UV-curable epoxy resin 616 cured in and above the battery contact pads 604a-604d by UV light can be applied simultaneously or in any suitable order.

[0048] Figure 7 A flexible PCB material 700 is illustrated, configured according to one or more embodiments to optimize the automated manufacturing of a flexible PCB (e.g., flexible PCB 602) with foldable arms. As shown, the flexible PCB material 700 can be configured with a tightly arranged grouping of flexible PCBs 702a-702d to minimize unused PCB material. Each flexible PCB 702a-702d may have four battery contact pads 704a-704d (…). Figure 7 Only one group of battery contact pads is marked in the diagram to accommodate two button (or similarly configured) batteries. Other embodiments configured for a single battery may have only two battery contact pads, such as battery contact pads 704a and 704d. Each of battery contact pads 704a-704d may be similar to or identical to battery contact pad 104. Each flexible PCB 702a-702d may also have a foldable arm 726 (only one is marked), which may be similar to or identical to foldable arm 626. Each flexible PCB 702a-702d may also have printed conductors 712a and 712b (only one is marked each), wherein printed conductor 712a is formed on one surface of foldable arm 726 to connect battery contact pads 704c and 704d to each other, and printed conductor 712b is formed on the opposite surface of foldable arm 726 to connect battery contact pads 704c and 704d to each other as well. Although in Figure 7 The diagram shows a single column of four flexible PCBs 702a-702d, but other embodiments of the PCB material may have other numbers of columns and / or closely arranged groups of flexible PCBs based on the configuration shown.

[0049] Figure 8A flexible PCB configuration 800 with attachable arms 826, according to one or more embodiments, is shown. The attachable arms are configured to mount and electrically connect a pair of button batteries 814a and 814b (or batteries with a similar configuration) to a flexible PCB 802. Batteries 814a and 814b can be positioned on the top surface 808 of the flexible PCB 802 above corresponding battery contact pads (not shown) formed in the flexible PCB 802. Each battery contact pad formed in the flexible PCB 802 can be coupled to… Figure 1A and 1B The battery contact pad 104 is similar to or identical to that of the battery contact pad 104. In those embodiments where the area requiring mounting one or more batteries has a certain rigidity to facilitate the assembly process of the flexible PCB 802, a non-conductive battery reinforcement 828 may be used to hold batteries 814a and 814b. The battery reinforcement 828 may be the same as or similar to the battery reinforcement 628 of FIG. 6.

[0050] like Figure 9 As shown, the attachable arm 826 is a separate component that may have battery contact pads 904a and 904b formed therein, which are connected to each other via printed conductors 912a on one surface of the attachable arm 826 and, in some embodiments, via printed conductors (not shown) on opposite surfaces of the attachable arm 826. Each of the battery contact pads 904a and 904b may be similar to or identical to battery contact pad 104. The attachable arm 826 may also have a single-ended terminal 930 formed at one end of the attachable arm 826, which is configured to insert into a connector 832 mounted on the top surface 808 of the flexible PCB 802. Figure 8In the dual-battery embodiment shown, the connection between the single-ended terminal 930 and the connector 832 may be purely physical (without electrical connection at the connector 832). In other embodiments using only a single battery, the connection between the single-ended terminal 930 and the connector 832 may be both physical and electrical (to complete the circuitry using a single battery), wherein the attachable arm 826 may include a printed conductor extending from the battery contact pad to the single-ended terminal 930 for electrical connection from the top surface terminal of the battery via the connector 832 to circuitry embossed on the top surface 808. In some embodiments, the connector 832 may be an FPC (Flexible Printed Circuit) connector. Other suitable connectors may be used. The shape of the attachable arm 826 and the placement of the connector 832 on the top surface 808 are configured such that the attachable arm 826, when inserted into the connector 832, positions the battery contact pad 904a above and above the battery 814a and the battery contact pad 904b above and above the battery 814b. Other shapes of the attachable arm 826 and arrangements of the connector 832 are possible. In embodiments using only a single battery, both the attachable arm 826 and the flexible PCB 802 may have only one properly positioned battery contact pad, and the length and / or shape of the attachable arm 826 and the placement of the connector 832 may be adjusted accordingly. The attachable arm 826 may be made of the same flexible PCB material as the flexible PCB 802. Alternatively, other suitable materials may be used to manufacture the attachable arm 826.

[0051] To achieve the mechanical and electrical connection between the attachable arm 826 and the batteries 814a and 814b, a conductive UV-cured epoxy resin, such as conductive UV-cured epoxy resin 216 or 616, can be disposed above and within each of the battery contact pads 904a and 904b from the top surface 908 of the attachable arm 826, and bonded to the surface. Figure 2 , 3 The batteries are cured in the same or similar manner as described in 4B, 5, and 6C. Similarly, batteries 814a and 814b can be combined with the above. Figure 2 , 3 The same or similar methods described in 4B, 5, and 6C are used to mechanically and electrically connect the top surface 808 of the flexible PCB 802 to the bottom surface of the flexible PCB 802 by applying and curing conductive UV-curable epoxy resin disposed above and in the two battery contact pads formed in the flexible PCB 802 from the bottom surface of the flexible PCB 802. It should be noted that the UV curing of the conductive UV-curable epoxy resin in the battery contact pads 904a, 904b and in the two battery contact pads formed in the flexible PCB 802 can be performed simultaneously or in any suitable order.

[0052] Figure 10A method 1000 for mounting a button (or similarly configured) battery to a flexible PCB using an arm, according to one or more embodiments, is illustrated. At process block 1002, method 1000 may include providing a flexible PCB in which at least one battery contact pad is formed. For example, as Figure 11 As shown, the flexible PCB 1102 may have one or more battery contact pads 1104a and / or 1104b formed therein. Each of the battery contact pads 1104a and 1104b may be similar to or the same as the battery contact pad 104.

[0053] At process block 1004, method 1000 may include positioning at least one button cell battery (or a similarly configured battery) on a flexible PCB above at least one battery contact pad. If more than one battery is to be mounted on the flexible PCB, each battery will be positioned above a corresponding battery contact pad. For example, as Figure 6A , 6B As shown in Figures 6 and 8, one or more batteries 614a, 614b, 814a and / or 814b can be positioned on the flexible PCB 602 or 802 above the respective battery contact pads. If two batteries are to be positioned (e.g., batteries 614a and 614b or batteries 814a and 814b), battery reinforcements 628 or 828 can be used to increase the rigidity of the battery mounting area of ​​the flexible PCB if needed.

[0054] At process block 1006, method 1000 may include positioning an arm above and over at least one battery, the arm having at least one battery contact pad formed therein and positioned above and over the at least one battery. If more than one battery is to be mounted on a flexible PCB, the arm has a corresponding battery contact pad formed therein for each battery. The battery contact pads are appropriately spaced apart from each other on the arm to accommodate positioning above the respective battery below the arm. One or more printed conductors formed on the arm can electrically connect the battery contact pads to each other. Reference Figures 6A-6C 8 and 9, the arm can be, for example, a foldable arm 626 or an attachable arm 826. In those embodiments where the arm is a foldable arm 626, method 1000 includes a folded arm at process block 1006 such that the foldable arm 626 is positioned above and over at least one battery, and one or more battery contact pads of the foldable arm 626 are respectively positioned above and over one or more batteries, as shown in Figure 1006. Figure 6B and 6C As shown in the diagram. In those embodiments where the arm is an attachable arm 826, method 1000 includes at process block 1006 inserting a single-ended terminal 930 of the attachable arm 826 into connector 832 such that the attachable arm 826 is positioned above and over at least one battery, and one or more battery contact pads of the attachable arm 826 are respectively positioned above and over one or more batteries, as shown in the diagram. Figure 8 As shown in the image.

[0055] At process block 1008, method 1000 may include applying conductive UV-curable epoxy resin to the accessible side of each contact pad, such that the epoxy resin fills the metallized vias of each contact pad and contacts the battery surface, as described above in conjunction with method 500. Figure 5 The process block 506 is similarly described.

[0056] And at process block 1010, method 1000 may include exposing each battery contact pad to ultraviolet light to cure a conductive ultraviolet-cured epoxy resin, as described above in combination with method 500. Figure 5 The process block 508 is similarly described. This establishes a mechanical and electrical connection between the battery and the battery contact pads formed in the arm and the flexible PCB.

[0057] Figure 12 A continuous glucose monitor (CGM) wireless transmitter 1200 with a flexible PCB is shown according to one or more embodiments. The CGM wireless transmitter 1200 includes a flexible PCB 1202 having one or more batteries 1204 mounted thereon. The one or more batteries 1204 can be... Figure 2 , 4B The CGM wireless transmitter 1200 is mounted on and electrically connected to the flexible PCB 1202 in any of the manner shown in 6B, 6C, and / or 8. The CGM wireless transmitter 1200 also includes a glucose sensor 1234 and wireless transmitter circuitry 1236, both fabricated on the top surface 1208 (or alternatively, the bottom surface) of the flexible PCB 1202 and electrically connected to each other via printed conductors 1212a, 1212b, and 1212c, connected to one or more batteries 1204, and possibly connected to other circuitry or components (not shown). A portion of the glucose sensor 1234 is inserted into the skin of the user's body and can be configured to continuously measure glucose levels, and the wireless transmitter circuitry 1236 can be configured to wirelessly transmit those glucose measurements to the CGM receiver and / or insulin pump. Other circuitry and circuitry components (not shown) may also be fabricated on the flexible PCB 1202. Advantageously, the CGM wireless transmitter 1200 is flexible and / or flexible, allowing it to conform to the surface of the user's body to which it is attached, thereby improving the adhesion of the CGM wireless transmitter 1200 to the skin surface and / or the user's comfort when wearing the CGM wireless transmitter 1200.

[0058] In some embodiments, other photocurable epoxy resins may be used, such as epoxy resins that are curable at other wavelengths (e.g., wavelengths of mid-ultraviolet, near-ultraviolet, violet, blue, or other visible wavelengths). For example, in some embodiments, methods 300, 500, and 1000 may be used with other photocurable epoxy resins, as in any circuit board configuration described herein.

[0059] While this disclosure is readily available to generate various modifications and alternatives, specific methods and apparatus embodiments have been illustrated by way of example in the accompanying drawings and are described in detail herein. However, it should be understood that the specific methods and apparatus disclosed herein are not intended to limit this disclosure, but rather to cover all modifications, equivalents, and alternatives falling within the scope of the claims.

Claims

1. A flexible printed circuit board, comprising: Metallized vias extending from a first surface of the flexible printed circuit board to an opposing second surface through the flexible printed circuit board; A battery, wherein the battery is in contact with the second surface and covers the metallized through-hole; A conductive photocurable epoxy resin is disposed on the first surface above and in the metallized via, such that the conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the metallized via. as well as A contact pad, wherein the contact pad includes the metallized vias arranged in a pattern and a plurality of other metallized vias, with printed conductors surrounding and electrically connecting each metallized via in the pattern.

2. The flexible printed circuit board of claim 1 further includes a printed conductor surrounding the metallized via on the first surface, such that the conductive path extends from the battery to the printed conductor.

3. The flexible printed circuit board of claim 1, wherein the conductive photocurable epoxy resin is disposed on the contact pad on the first surface above and in each metallized via in the pattern, such that the conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the printed conductor.

4. The flexible printed circuit board according to claim 1, wherein the battery is a button battery.

5. The flexible printed circuit board according to claim 1, further comprising a wireless transmitter circuit fabricated on a first surface of the flexible printed circuit board.

6. A continuous glucose monitor, comprising: The flexible printed circuit board according to claim 5; as well as A sensor is connected to the wireless transmitter circuitry, the sensor being configured to measure glucose levels.

7. A flexible printed circuit board, comprising: A first segment and a second segment, wherein the first segment is separated from the second segment by a slit extending from the top surface to the bottom surface through the flexible printed circuit board; A first metallized through-hole extends from the top surface to the bottom surface through the flexible printed circuit board in the first segment; A second metallized via extends from the top surface to the bottom surface through the flexible printed circuit board in the second section; A battery, which is inserted into the slit such that the battery contacts the bottom surface of the first segment below the first metallized through-hole and the top surface of the second segment above the second metallized through-hole; A first conductive photocurable epoxy resin is disposed on the top surface of the first segment above and in the first metallized via, such that the first conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the first metallized via. as well as A second conductive photocurable epoxy resin is disposed on the bottom surface of the second segment above and in the second metallized via, such that the second conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the second metallized via.

8. The flexible printed circuit board of claim 7, further comprising a first contact pad in the first segment, wherein the first contact pad includes the first metallized via and a first plurality of other metallized vias arranged in a first pattern, and a first printed conductor surrounds and electrically connects to each metallized via in the first pattern.

9. The flexible printed circuit board of claim 8, further comprising a second contact pad in the second segment, wherein the second contact pad includes the second metallized via and a plurality of other metallized vias arranged in a second pattern, and a second printed conductor surrounds and electrically connects to each metallized via in the second pattern.

10. The flexible printed circuit board of claim 7, further comprising a wireless transmitter circuit fabricated on a first surface of the flexible printed circuit board.

11. A continuous glucose monitor, comprising: The flexible printed circuit board according to claim 10; as well as A sensor is connected to the wireless transmitter circuitry, the sensor being configured to measure glucose levels.

12. A flexible printed circuit board, comprising: A first metallized via extends from the top surface to the bottom surface of the flexible printed circuit board through the flexible printed circuit board. A battery, wherein the battery is positioned on the top surface above the first metallized through-hole; A first conductive photocurable epoxy resin is disposed on the bottom surface of the flexible printed circuit board above and in the first metallized via, such that the first conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the first metallized via. An arm having a second metallized through-hole extending from the top surface to the bottom surface of the arm, the arm being positioned on the battery such that the bottom surface of the arm contacts the battery and the second metallized through-hole is above the battery; as well as A second conductive photocurable epoxy resin is disposed on the top surface of the arm above and within the second metallized via, such that the second conductive photocurable epoxy resin contacts and adheres to the battery and provides a conductive path from the battery to the second metallized via.

13. The flexible printed circuit board of claim 12, wherein the arm initially extends outward from the flexible printed circuit board and is foldable onto the battery.

14. The flexible printed circuit board of claim 12, further comprising a connector on the top surface of the flexible printed circuit board, wherein the arm has an end that inserts into the connector.

15. The flexible printed circuit board of claim 14, wherein the connector is a flexible printed circuit connector.

16. The flexible printed circuit board of claim 12, further comprising a non-conductive reinforcement sized to hold the battery, the thickness or height of the non-conductive reinforcement not exceeding the thickness or height of the battery.

17. The flexible printed circuit board of claim 12, further comprising a first contact pad, the first contact pad including the first metallized via and a first plurality of other metallized vias arranged in a first pattern, the first printed conductor surrounding and electrically connecting each metallized via in the first pattern.

18. The flexible printed circuit board of claim 12, wherein the arm includes a second contact pad, the second contact pad including a second metallized via and a plurality of other metallized vias arranged in a second pattern, and a second printed conductor surrounding and electrically connecting each metallized via in the second pattern.

19. A continuous glucose monitor, comprising: The flexible printed circuit board according to claim 12 further includes a wireless transmitter circuit fabricated on the top surface of the flexible printed circuit board. as well as A sensor is connected to the wireless transmitter circuitry, the sensor being configured to measure glucose levels.

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