Note: Descriptions are shown in the official language in which they were submitted.
lZ777~3
PORTABLE RADIO TRANSCEIVER HOUSING
STRUCTURALLY SUPPORTED BY A BATTERY
Backaround Art
The present invention is generally related to radio
transceivers and more particularly related to an improved
portable radio transceiver housing structurally supported
by a battery.
In the prior art, batteries for portable radio
transceivers were typically designed to be an appendage
to or to be inserted into and removed from a receptacle
in the portable transceiver housing. For example, the
battery was often an appendage to a side of the portable
radio transceiver housing (see U.S. design patent no.
D2698~3). However, none of the prior art portable radio
transceivers took advantage of the heat sinking,
electrical shielding and structural characteristics of
batteries.
Ob~ects and Summary of the Invention
Accordingly, it is an object of the present
invention to provide an improved electronic circuitry
housing that takes advantage of the heat sinking,
electrical shielding and structural characteristics of a
battery.
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It is another object of the present invention to
provide an improved electronic circuitry housing
including a battery that is a structural element thereof.
It is another object of the present invention to
provide an improved, light-weight electronic circuitry
housing including a battery that strengthens the housing,
shields electrical components therein and sinks heat from
electrical components therein.
It is yet another object of the present invention to
provide an improved electronic circuitry housing
including a battery that is a structural element thereof,
whereby the housing is stronger with the battery than
- without the battery.
Briefly described, the present invention
encompasses an improved electronic circuitry housing
including a battery that is a structural element thereof.
The housing includes a battery having first and second
edges and first and second opposing flat, rigid surfaces,
a U-shaped panel having first and second side portions
and a center portion, and means for attaching the edges
of the battery to the side portions of the panel whereby
the battery and the panel substantially enclose and
support the electronic circuitry, which is disposed on
the inner surface of the center portion of the panel.
Brief Description of the Drawings
Figure 1, with parts broken away, is a perspective
view of a portable radio transceiver embodying the
present invention.
Figure 2 is an exploded perspective view of the
housing of the portable radio transceiver in Figure 1.
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Figure 3 is an end view of the portable radio
transceiver housing in Figure 2.
Figure 4 is a partial cross-sectional view of a
printed circuit panel in the portable radio transceiver
housing in Figure 2.
Figure 5 is an exploded perspective view of the end
cap of the portable radio transceiver housing in Figure
2.
Figure 6 is a cross-sectional view of another
portable radio transceiver housing embodying the present
invention.
Figure 7 is a partial top view of the portable radio
transceiver in Figure 6.
Figure 8 is a perspective view of a surface-mount
connector used to interconnect the three printed circuit
panels in the portable radio transceiver housing in
Figure 2.
Figure 9 is a cross-sectional view of the surface-
mount connector in Figure 8 as it may be used to
interconnect the three printed circuit panels in the
portable radio transceiver housing in Figure 2.
In Figure 1, there is illustrated a perspective view
of a portable radio transceiver 100 embodying the present
invention. Transceiver 100 includes an outer covering
102 preferably of compliant plastic and an inner shell or
housing 104 preferably comprised of sheet metal.
~ransceiver 100 also includes keyboard 106, display 108,
speaker 110 and microphone port 112 for communicating in
a radio system. Transceiver 100 may be advantageously
utilized in a variety of radio systems, such as, for
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exiample, cellular radiotelephone systems and trunked
radio systems.
Referring next ot Figure 2, there is illustrated an
exploded perspective view of the housing 104 in the
portable radio transceiver 100 in Figure 1. A stick
battery 210 inserts into housing 104 and is a structural
element thereof. The elements of housing 104 may be made
of light-weight sheet metal since battery 210
contributes significantly to the structural strength of
the housing. In the preferred embodiment of the present
invention, battery 210 includes three to five individual
cells which are stacked together as a stick.
Housing 104 in Figure 2 includes three printed
circuit panels 212, 213 and 214, a stick battery 210, a
battery tube 211, side rails 206 and 207 and end caps 202
and 203. In the preferred embodiment illustrated in
Figure 2, panels 212, 213 and 214, side rails 206 and 207
and battery tube 211 are made of sheet metal, and the
exterior portions of end caps 202 and 203 are made of
plastic and metal. Panel 212 is the logic printed
circuit panel and includes on one side keyboard 106 and
display 108, and on the other side electronic circuitry,
which performs the signalling and control functions of
the portable transceiver 100. The electronic circuitry
on each of the panels 212, 213 and 214 includes surface
mountable electrical components 224 ~soldered to an
electrical circuitry layer, which together with a
dielectric layer is laminated to panel 2~2 (shown in more
detail in Figure 4).
Panel 213 in Figure 2 is the transmitter printed
circuit panel and includes male connector 220 which
interconnects panels 212, 213 and 214, and on one side
electronic circuitry, which is the radio frequency (RF)
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transmitter of the portable transceiver 100. Male
connector 220 extends on both sides of panel 213 for
coupling control, RF and audio signals by way of
corresponding female connectors 222 and 223 between the
transmitter circuitry, logic circuitry and receiver
circuitry (shown in more detail in Figures 8 and 9).
Panel 213 also includes two connecting pins 242 and 243
that couple transmitter and receiver RF signals to
serpentine antenna that is located in end cap 203 ~shown
in more detail in Figure 3). Panel 213 has an I-beam
cross-section for imparting strength to housing 104. One
side of panel 213 inserts into a channel in battery tube
211 for structurally coupling panel 213 to battery 210.
In the preferred embodiment illustrated in Figure 2,
battery 210 and tube 211 have canted sides 240 and 241
for resisting torsionally applied forces. These features
of battery 210, tube 211 and panel 213 are illustrated in
more detail in the cross-sectional view in Figure 3.
Panel 214 in Figure 2 is the receiver printed
circuit panel and includes on one side electronic
circuitry, which is the RF receiver of the portable
transceiver 100. Panel 214 includes flanges 226 and 232
which insert into slots 230 and 236 in end caps 203 and
202, respectively, for positioning and retaining panel
214 in housing 104. Similarly, edges 227 and 233 of
panel 213 insert into slots 231 and 237 in end caps 203
and 202, respectively, for positioning and retaining
panel 213 in housing 104; and flanges 228 and another
flange (similar to flange 228 but not shown) which insert
into slots 232 and 238 in end caps 203 and 202,
respectively, for positioning and retaining panel 212 in
housing 104. Once panels 212, 213 and 214 in Figure 2
are positioned in end caps 202 and 203, side rails 206
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and 207 may be slipped onto the edges of panels 212, 213
and 214 for completing assembly of housing 104. The
elements of housing 104 are essentially held together by
interlocking geometry which causes side rails 206 and 207
and panels 212j 213 and 214 to be one structure. End cap
202 includes a battery retaining tab (not shown) and
metal plate 271 which has slots 236, 237 and 238. Metal
plate 271 is connected to end cap 202 by screws (not
shown) or adhesive. End cap 203 (shown in more detail in
Figure 5) has an outer portion 270 which is connected to
inner portion 269 by screws (not shown) or adhesive.
Once assembled, housing 104 is slipped into outer
covering 102. Thus, transceiver 100 may be quickly and
easily assembled without using screws 268.
Referring next to Figure 3, there is illustrated an
end view of housing 104 where end cap 203 has been
removed. The center portion 250 of side rail 207 is
shaped to capture the flanged side 259 of panel 213. The
center portion 251 of side rail 206 is shaped to fit over
side 240 of battery tube 211. In other embodiments,
center portion 251 canted of side rail 206 may be shaped
to capture canted side 240 of battery tube 211. Battery
tube 211 includes side rails 261 shaped to capture the
flanged side 258 of panel 213. Side rail 261 is attached
by spot welding or other suitable means to canted side
241 of battery tube 211. Contacts 264 on battery 210
feed a DC voltage to the electronic circuitry by way of
contacts on end cap 203 which in turn are coupled to leaf
contacts (not shown) that connect to corresponding pads
- on the transmitter circuitry on panel 213 when housing
104 is assembled. Pins 242 and 243 coupled transmitter
and receiver signals to an antenna located in end cap 203
(shown in more detail in Figure 5). Flanges 226 and 228
insert into slots 230 and 232, respectively, in end cap
203 as explained hereinabove with respect to Figure 2.
The edges 244-247 of side rails 206 and 207 in
Figure 3 include channels which slide into corresponding
channels in the edges 252-255 of panels 212 and 214. The
center portion 250 of side rail 207 is also shaped to
capture the I-beam side 259 of panel 213. According to a
feature of the present invention, the edges 244-247 of
side rails 206 and 207 are also shaped to exert a spring
force on the edges 252-255 of panels 212 and 214 when
housing 104 is assembled. Furthermore, panels 212, 213
and 214 are strengthened by battery 210 since battery
210 is a structural element of housing 104. As a result,
panels 212, 213 and 214 may be made out of sheet metal.
The electronic circuitry on each of the panels 212,
213 and 214 is also illustrated in greater detail in
Figure 3. The logic circuitry on panel 212 includes
components 272 which, in the preferred embodiment, are
soldered to an electrical circuitry layer, which together
with a dielectric layer is laminated to panel 212 (shown
in more detail in Figure 4). Similarly, the transmitter
circuitry on panel 213 includes components 274, and the
receiver circuitry on panel 214 includes components 273.
The components 272 on panel 212 are electrically shielded
from the RF signals on panels 213 and 214 since panels
212, 213 and 214 are preferably made of sheet metal and
are coupled to signal ground. Furthermore, large
components such as component 273 on panel 214 and
component 274 on panel 213 may be offset relative to one
another such that they may have a vertical length
slightly less than the vertical distance between panels
212 and 214.
Referring next to Figure 5, there is illustrated an
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exploded perspective view of end cap 203 of the portable
ra,dio transceiver housing 104 in Figure 2. End cap 203
includes serpentine antenna therein for transmitting and
receiving RF signals. End cap includes inner portion
26g, outer portion 270 and cover 514. Inner portion 269
in¢ludes metal ground plane 502 and circuit board 504.
Circuit board 504 includes posts 506 and 507 which are
coupled by stripline circuitry to receptacles 509 and
508, respectively. Outer portion 270 of end cap 203
includes a circuit board 518 having a serpentine loading
circuit 512. The serpentine loading circuit 512 is
formed by a zig-zag stripline. Pins 242 and 243 on panel
213 in Figure 2 insert into receptacles 509 and 508,
respectively for connecting the transmitter and receiver
circuitry to the antenna formed by posts 506 and 507 and
serpentine loading circuitry 512. The foregoing antenna
circuitry is described in more detail in U.S. Patent No.
4,571,595, issued February 18, 1986, entitled "Dual Band
Transceiver Antenna: and invented by James P. Phillips
and Henry L. Kazecki.
In Figure 4, there is illustrated a partial cross-
sectional view of printed circuit panel 402
representative of printed circuit panels 212, 213 and 214
in the portable radio transceiver housing 104 in Figure
2. The representative printed circuit panel 402 in
Figure 4 includes an electrical circuitry layer 406 and a
dielectric layer 404 which are colaminated to panel 402.
Any suitable adhesive 410 may be utilized to laminate or
bond dielectric layer 404 to panel 402 and to bond
electrical circuitry layer 406 to dielectric layer 404.
Electrical circuitry layer 406 includes conductive
plating 412 on the top and/or bottom surface thereof for
providing circuit paths for electrical signal continuity
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between such electrical components and connectors.
Components 432 are preferable surface mount components.
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g
Panel 402 in Figure 4 includes a plurality of mesas
422 which are indentations extending up between
corresponding holes in the dielectric layer 404 and
electrical circuitry layer 406. Mesas 422 protrude
through corresponding holes in the dielectric layer 404
and at least partially through corresponding holes in
electrical circuitry layer 406. Mesas 422 are preferably
bonded by solder 408 to plating 412. In the preferred
10 embodiment, mesas 422 have a height of approximately 0.20
inches and a diameter of 0.040 inches; metal panel 402
has a thickness of 0.015 inches; dielectric circuitry
layer has a thickness of 0.010 inches; and electrical
circuitry layer has a thickness of 0.010 inches. Since
panel 402 is preferably made of a conductive metal and
coupled to signal ground, mesas 422 couple signal ground
to plating 412 on the top surface of layer 406.
~urthermore, stripline transmission lines 414 may be
produced between grounded plating 412 and grounded
metallic panel 404. Stripline transmission lines 414 may
be used to provide signal paths in a high freguency
circuit, such as those found in RF signal transmitters
and receivers. Moreover, in addition to providing signal
ground connections, mesas 422 also provide paths for the
transfer of dissipated heat from an electrical component
432 on layer 406 to metal panel 402. When mesas 422 are
used for heat sinking purposes, the electrical component
432 dissipating the heat may be mounted at least
partially on one or more mesas 422, and the mesas 422 may
be elongated slots or rectangular indentations or may be
indentations shaped to conform to a particular component.
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Referring next to Figure 6, there is illustrated a
cross-sectional view of another portable radio
transceiver housing 600 embodying the present invention.
As shown in Figure 6, the ideal battery encompassing the
present invention is a flat battery which also becomes a
load-bearing surface of the housing 600. The battery
walls are not only enclosures for one or more cells but
also a structural element of the housing.
Housing 600 in Figure 6 includes flat battery 602, a
first U-shaped panel 604 and a second U-shaped panel 606.
U-shaped panel 604 has first and second side portions 661
and 662, respectively, and a center portion 663 having
inner and outer surfaces. U-shaped panel 606 has first
and second side portions 671 and G72, respectively, and a
center portion 673 having inner and outer surfa~es.
Panels 604 and 606 each include electrical components
624 soldered to a circuitry layers 611 and 641, which is
colaminated with dielectric layers 610 and 640 to inner
surfaces of the center portions 663-673, respectively of
panels 604 and 606 by any suitable means. Colaminating
circuitry layers 611 and 641 and dielectric layers 610
and 640 to inner surfaces of the center portions 663 and
673 of panels 604 and 606 strengthens panels 604 and 606,
thereby enhancing the structural integrity of housing
600. In other embodiments, circuitry layer 611 and
dielectric layer 610 may be bonded by adhesives or other
suitable means to panels 604 and 606. Connectors 631 and
632 provide for interconnection of electrical signals
between panels 604 and 606, respectively. Although
housing 600 is shown with two panels 604 and 606, only
one panel 606 need be utilized in practicing the present
invention.
Battery 602 in Figure 6 includes edges having
lZ77 7i3
channels 644 which mate with corresponding channels 642
in first and second side portions 661 and 662 of panel
604. Channels 642 and 644 extend the entire length of
battery 602 and panel 604, respectively. Housing 600 may
be assembled by sliding battery 602 into panel 604.
Assembly is completed by adding end cap 650, such as caps
202 and 203 in Figure 2, which end cap 650 maybe attached
to battery 602 and panel 604 by screws, adhesive or other
suitable means.
As can be seen form the partial top view of housing
600 in Figure 7, battery 602 is flat and has a length
substantially the same as the overall length of housing
600. According to an important feature of the present
invention, if battery 602 is at least one-third as long
as housing 600, battery 602 will be a structural element
of housing 600. In other words, housing 600 is stronger
with battery 602 th~n without it. When battery 602 has a
length that is less than one-fourth that of housing 600,
battery 602 becomes a load to housing 600 rather than a
structural element. However, in such cases, battery 602
may also be a structural element of housing 600 if
attached to other elements by key ways, screws, brackets,
clamps or other suitable means.
For example, the stick battery 210 in Figure 2
likewise functions as a structural element of the housing
since it picks up a significant portion of applied
inertial and static loads. By means of the canted
surfaces 240 and 241 of battery 210 in Figure 3, the
torsional strength of the stick battery 210 is used to
resist rotational torques applied along the léngth of
housing 104 (X-axis). Similarly, a torque about the Y-
axis (width) or a load along the Z-axis (height) is
1~713
rlesisted by canted surfaces 240 and 241, side rail 261
and battery tube 211 when sufficient deflection of tube
211 occurs for battery 210 to be loaded as a beam. A
load along the Y-axis is resisted by canted surfaces 240
and 241 and by battery 210 when tube 211 is deflected
such that it bears on battery 210.
Components 624 in Figure 6 dissipate varying amounts
of heat during operation. Often only one or a few of
the components 624 will dissipate a large fraction of the
total power dissipated by the electronic apparatus in
housing 600 producing a hot spot. Conventional methods
minimize the effect of such hot spots by heat sinking
such components to a heat spreader and adding to the
housing thermal insulation, thereby forcing the internal
volume of the housing to rise in temperature and hence
equalize the outside surface temperature thereof.
However, such conventional methods are undesirable since
additional weight and volume is required and higher
temperatures are produced which reduce the reliability
of the electronic circuitry.
According to the present invention, the thermal mass
and heat conduction properties of battery 602 may be
utilized to equalize temperatures due to power
dissipating within the housing 600 without adding
additional mass. Since the lower surface of battery 602
is adjacent to and in contact with panel 606, heat is
conducted away from panel 606 by battery 602. Heat
transfer can be enhanced by coating the adjoining
surfaces of battery 602 and panel 606 with a suitable
thermally conductive compound 683. Thus, in housing 600,
components 624 dissipating large amounts of heat are
preferably mounted on panel 606 such that battery 602
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absorbs,spreads and conducts away heat dissipated by
such components 624.
A multi-cell battery, such as battery 602 in Figure
6 or battery 210 in Figure 2, may be implemented by two
methods. In both methods, some form of liquid or gas
tight cell enclosure is required to electro-chemically
separate each cell from the other. First, a very weak or
thin outer enclosure only sufficient to maintain the
moisture of each cell could be provided around each
electrode set thereof. Such cells would be installed
into a battery tube or housing which provides the
strength needed to contain the contents of the cells and
also acts as a structural element of housing. Secondly,
lS individual cells may be provided with individually strong
enclosures which when coupled together act as a
structural element of housing.
Turning to Figure 8, there is illustrated a
perspective view of a surface-mount connector 800 used
to interconnect two or more printed circuit panels, such
as, for example, panels 212, 213 and 214 in the portable
radio transceiver housing 104 in Figure 2. Connector 800
includes a plurality of pins 802 each coupled to a spring
contact 804 and extending through plastic header 806.
Plastic header 806 includes portions 810 that insulate
corresponding pins 802 from metal panel 213 ~shown in
more detail in Figure 9).
Two different methods may be used to manufacture
connector 800 in Figure 8. According to the first
method, the contacts 804 are insert molded into the
plastic header 806 and pins 802 are press fit in place
after molding is completed. The contacts 804 are
produced on a "comb" with a slightly extruded hole into
which the pins 802 with a cold-formed, bulged center
. .
.
12777i3
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section can be pressed. This method relatively
inexpensively provides a generic molded connector 800
that gets its identity after the unique pin 802 is
pressed in place. A high temperature plastic is used for
header 806, and pins 802 can be produced by a low cost
cold heading process. According to a relatively more
expensive second method, the pins 802 and spring
contacts 804 are welded or high temperature soldered
together and then insert molded into the plastic header
806 using a high temperature solder.
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Referring to Figure 9, there is illustrated a cross-
sectional view of the surface-mount connector in Figure 8
as it may be used to interconnect the three printed
circuit panels in the portable radio transceiver housing
in Figure 2. Three male connectors 912, 913 and 914 and
three female connectors 902, 903 and 904 are shown.
Connectors 902, 903 and 904 are conventional surface-
mount female connectors each including a pair of
contacts 920 and 921 for each pair of pins in connector
912. Connector 912 is surface mounted to panel213 and
connected to panel 212 by way of surface-mounted
connector 902 and to panel 214 by way of surface-mounted
connector 903. Connector 914 is surface mounted to the
topside (keyboard, display and speaker side) of panel 212
and connected to the bottom side of panel 212 by way of
surface-mounted connector 904. As a result, the
circuitry ~nd dielectric layers on the top side of panel
212 may be removed for replacing the keyboard, display
and speaker assembly. Connector 913 is surface mounted
to panel 214 for providing external contacts 925, which
may be used to couple transceiver 100 to an external
speakerphone, power amplifier or other peripheral
devices.
In summary, a unique portable radio transceiver
housing has been described that includes a battery which
is a structural element thereof. The battery not only
strengthens the housing, but also provides shielding
against electromagnetic radiation and sinking of heat
dissipated by electrical components. Since the battery
is a structural element of the housing, the housing
elements can be implemented with sheet metal to produce
both a light-weight and structurally strong housing. the
portable radio transceiver housing of the present
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invention may be advantageously utilized in a variety of
radio systems including battery-operated radio
transceivers, such as, for example, cellular
radiotelephone systems and trunked radio systems.
