3D Printed PCB Support Block With Targeted Vacuum Channels
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Solution Overview
Problem
Existing PCBA support blocks are heavy, expensive, and inefficient, with high dimensional tolerances and suboptimal vacuum application, leading to potential damage to components and increased shipping and ergonomic issues.
Innovation Solution
A 3D printed support block with a single-piece design, optimized vacuum channels, and offset recessed surfaces for improved flatness and targeted vacuum application, using additive manufacturing to minimize material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional two-block support blocks are used, then components on the bottom side of PCBAs can be accommodated, but dimensional tolerances accumulate and surface flatness deteriorates
Solution Approach 1:
The patent merges the traditional two-block support block design into a single integrated support block. This single block incorporates both the support function and the component accommodation function through integrated recesses and cavities, eliminating the interface between two separate blocks and thus preventing tolerance accumulation while maintaining adaptability to accommodate various component configurations on the bottom side of PCBAs
2Reliability
If vacuum is applied through the entire bottom surface, then PCBA is securely held, but vacuum efficiency decreases due to large volume
Solution Approach 1:
The patent segments the vacuum application area by providing multiple discrete vacuum holes distributed across the bottom surface of the support block rather than applying vacuum across the entire surface. This segmentation reduces the total volume that needs to be evacuated while maintaining secure holding of the PCBA through multiple localized vacuum contact points, thereby improving vacuum efficiency
Solution Approach 2:
The patent implements local quality by concentrating vacuum application at specific strategic locations through the vacuum holes rather than uniform distribution. The vacuum holes are positioned to contact specific areas of the PCBA bottom surface, providing localized holding force where needed while leaving other areas open, thus reducing the overall vacuum volume and improving efficiency
3Strength
If aluminum material is used for support blocks, then strength and durability are achieved, but weight increases causing ergonomic issues
Solution Approach 1:
The patent applies local quality by using different materials for different parts of the support block. The top surface that contacts the PCBA is made of a lighter material such as plastic or composite, while only the critical structural components that require high strength (such as the vacuum holes and mounting features) are made of aluminum or other strong materials. This reduces overall weight while maintaining necessary strength and durability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D printed support block provides enhanced flatness, reduced weight, and efficient vacuum distribution, improving component safety and reducing manufacturing time and shipping costs while enabling on-site production and recycling.
Implementation Method 1
a bottom surface with a vacuum connection; a top surface with at least one vacuum hole; and at least one vacuum channel extending from the vacuum connection to the at least one vacuum hole
Data Source
AI summary
Support blocks for printed circuit boards (PCB's) and printed circuit board assemblies (PCBA's), wherein the support blocks are produced from a 3D printing process. The support block including a bottom surface having a vacuum connection; a top surface having at least one vacuum hole; at least one recessed surface that is offset from the top surface; and at least one vacuum channel extending from the vacuum connection to the at least one vacuum hole.