# US 9,039,442 B2 · Solder-less electrical assembly

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- Number: US 9,039,442 B2
- Document ID: US9039442B2
- Status: Granted
- Kind: B2
- Application number: 13/646,489
- Filed: 2012-10-05
- Published: 2013-12-12
- Granted: 2015-05-26
- Earliest claimed: 2011-11-10
- Applicants: Carmen Rapisarda
- Inventors: Carmen Rapisarda
- Web page: https://patentgrep.com/patent/US9039442B2

## CPC

- F21V 23/06: the elements being coupling devices {, e.g. connectors}
- H01M 50/216: adapted for button or coin cells
- H01M 50/50: Current conducting connections for cells or batteries
- H01R 4/2406: having needles or pins
- H01R 4/26: Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact ({H01R4/188, H01R4/203, H01R4/5075 take precedence}; using shape memory materials H01R4/01)
- H01R 12/592: {connections to contact elements}
- H01R 12/79: connecting to rigid printed circuits or like structures
- H01R 13/41: by frictional grip in grommet, panel or base
- H01R 13/506: assembled by snap action of the parts
- H01R 25/003: {the coupling part being secured only to wires or cables}
- H05K 1/184: associated with components inserted in holes through the PCBs and wherein terminals of the components are connected to printed contacts on the walls of the holes or at the edges thereof or protruding over or into the holes
- H05K 3/325: by abutting or pinching; Mechanical auxiliary parts therefor
- H05K 5/0026: {provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units}
- H05K 5/0091: {Housing specially adapted for small components (for resistors H01C; for capacitors H01G; for integrated circuits H10W99/00)}
- F21Y 2115/10: Light-emitting diodes [LED]
- H01M 2220/30: Batteries in portable systems, e.g. mobile phone, laptop
- H01R 13/665: {with built-in electronic circuit (H01R13/70, H01R13/719 take precedence)}
- H05K 2201/10037: Printed or non-printed battery
- H05K 2201/10106: Light emitting diode [LED]
- H05K 2201/10363: Jumpers, i.e. non-printed cross-over connections
- H05K 2201/10393: Clamping a component by an element or a set of elements
- H05K 2203/0173: Template for holding a PCB having mounted components thereon
- Y02E 60/10: Energy storage using batteries
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A PCB assembly can be attached to hold one or more such assemblies. A resilient PCB housing holds a PCB by an interference fit while conductive wires are inserted into its wire cavity so that exposed portions of conductive wires make electrical contact with electrical traces of the PCB which is biased by wire insulation. Two conductors can be held by the PCB housing which are forced into electrical contact with the PCB when it is inserted into the resilient PCB housing which then biases such contacts. A switch can also be held by a switch interference fit with the resilient PCB housing such that its leads are biased against the PCB by the resilient PCB housing.

## Claims

### Claim 1

An electrical assembly, comprising:
a first block housing;
a ribbon block;
a printed circuit board (“PCB”) having a surface with a plurality of electrically conductive elements located between a first end of the PCB and a second end of the PCB; and
a ribbon wire assembly held within the ribbon block by an interference fit;
wherein the ribbon wire assembly is comprised of one or more wires having an insulated covering with a stripped portion at an end thereof;
wherein the first block housing and the ribbon block are connected by a snap fit to form a completed assembly which holds first and the second ends of the PCB;
wherein the first end of the PCB is held within a PCB opening in the first block housing and the second end of the PCB is held within the ribbon block; and
wherein each stripped portion of the one or more wires of the ribbon wire assembly is held in electrical contact with one of the electrically conductive elements of the surface of the PCB without the use of any solder by the ribbon block when the second end of the PCB is held within the ribbon block.

### Claim 2 (depends on 1)

The electrical assembly of claim 1, further comprising:
a battery held within a battery block opening in the first block housing;
a first conductor and a second conductor held within the first block housing, each of the first and second conductors having a first lead in mechanical and electrical conduct with the battery without the use of any solder and a second lead in mechanical and electrical conduct with the PCB without the use of any solder, the first lead of the first conductor being electrically connected to a positive terminal of the battery and the first lead of the second conductor being electrically connected to a negative terminal of the battery.

### Claim 3 (depends on 1)

The electrical assembly of claim 1, wherein the first end of the PCB is held within the PCB opening in the first block housing by a first interference fit and the second end of the PCB is held within the ribbon block by a second interference fit.

### Claim 4 (depends on 1)

The electrical assembly of claim 1, wherein no solder is used in the assembly.

### Claim 5 (depends on 2)

The electrical assembly of claim 2, wherein no solder is used in the assembly.

### Claim 6

An assembly, comprising:
a first block housing;
a printed circuit board (“PCB”) having a first end held in a PCB cavity of the first block housing by a PCB interference fit without the use of any solder;
a ribbon block attached to the PCB, said ribbon block holding a second end of the PCB;
a first and a second wire, each of which is comprised of a conductor which is insulated by an insulator, said first and second conductive wires being held by the ribbon block; and
an electrical component having two conductive leads, each of which is electrically connected to the conductor of one of the first and the second wires, said electrical component being attached to the first and the second wires;
wherein each of the first and the second wires has a stripped portion at an end thereof electrically connected to an electrically conductive element of the PCB and one of the first and the second wires without the use of any solder when the ribbon block is attached to the PCB.

### Claim 7 (depends on 6)

The assembly of claim 6, wherein the insulator of each of the first and the second wires is resilient and wherein the PCB has a top surface having a first and a second electrical trace.

### Claim 8 (depends on 7)

The assembly of claim 7, wherein the insulator of the first conductive wire biases the exposed portion of the conductor of the first conductive wire into electrical contact with the first electrical trace and the insulator of the second conductive wire biases the exposed portion of the conductor of the second conductive wire into electrical contact with the second electrical trace when the ribbon block is attached to the PCB.

### Claim 9 (depends on 7)

The assembly of claim 7, further comprising a first conductor held by the first block housing wherein insertion of the PCB into the PCB cavity to form the PCB interference fit forces the first conductor into a first electrical contact with a first conductive member of the PCB and causes the first block housing to bias the first conductor against the first conductive member of the PCB.

### Claim 10 (depends on 9)

The assembly of claim 9, further comprising a second conductor held by the first block housing wherein insertion of the PCB into the PCB cavity to form the PCB interference fit forces the second conductor into a second electrical contact with a second conductive member of the PCB and causes the first block housing to bias the second conductor against the second conductive member of the PCB.

### Claim 11

An assembly, comprising:
a first block housing;
a first and a second conductor held by the first block housing;
a printed circuit board (“PCB”) which has a top surface having a first and a second electrical trace, wherein said PCB is held in a PCB cavity of the first block housing by an interference fit without the use of any solder;
a ribbon block attached to the PCB;
a first and a second wire, each of which is comprised of a conductor which is insulated by an insulator which is resilient and has a stripped portion at an end thereof, said first and second conductive wires being held by the ribbon block;
an electrical component having a first conductive lead and a second conductive lead, the first conductive lead being electrically connected to the conductor of the first wire distant from the exposed portion of the conductor of the first wire, the second conductive lead being electrically connected to the conductor of the second wire distant from the exposed portion of the conductor of the second wire, said electrical component being attached to the first and the second wires;
wherein the first wire is electrically connected to the first electrical trace and the first conductive lead without the use of any solder and the second wire is electrically connected to the second electrical trace and the second conductive lead without the use of any solder; and
wherein insertion of the PCB into the PCB cavity to form the PCB interference fit forces the first conductor into electrical contact with a first conductive member of the PCB and causes the first block housing to bias the first conductor against the first conductive member of the PCB; and
wherein insertion of the PCB into the PCB cavity to form the PCB interference fit forces the second conductor into a second electrical contact with a second conductive member of the PCB and causes the first block housing to bias the second conductor against the second conductive member of the PCB.

### Claim 12 (depends on 11)

The assembly of claim 11, wherein each of the first and the second conductors is held within a unique channel of the resilient housing which is independently resilient.

### Claim 13 (depends on 11)

The assembly of claim 11, further comprising: a battery held in a battery opening of the first block housing by a battery interference fit without the use of any solder; wherein each of the first and the second conductors have a first lead in mechanical and electrical contact with the battery without the use of any solder and a second lead in mechanical and electrical contact with the PCB without the use of any solder, the first lead of the first conductor being electrically connected to a positive terminal of the battery and the first lead of the second conductor being electrically connected to a negative terminal of the battery.

### Claim 14 (depends on 13)

The assembly of claim 13, wherein the first and the second conductors have a u shape before said first and second conductors are assembled to the first block housing and at least one of the first leads of the first and the second conductors is bent over during assembly.

### Claim 15 (depends on 13)

The assembly of claim 13, further comprising a switch held by a switch interference fit with the first block housing, said switch having a first switch lead in electrical contact with a third conductive member of the PCB, the first switch lead being biased against the PCB by the first block housing.

### Claim 16 (depends on 13)

The assembly of claim 13, further comprising six or more LEDs that are electrically connected to the first and the second conductive wires and are energized by the battery to emit light.

### Claim 17 (depends on 13)

The assembly of claim 13, further comprising four or more groups of LEDs that are energized by the battery to emit light, and each of said four or more groups of LEDs are operable to be lit in parallel.

### Claim 18 (depends on 13)

The assembly of claim 13, wherein no solder is used in the assembly.

### Claim 19 (depends on 11)

The assembly of claim 11, wherein the electrical component is not comprised of a light emitting diode.