3D-Printed PCB Support Block With Integrated Vacuum Channels
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Solution Overview
Problem
Existing PCBA support blocks are heavy, expensive, and inefficient, with high dimensional tolerances and ergonomic issues, and require off-site manufacturing, leading to increased shipping costs and potential injuries.
Innovation Solution
A 3D printed support block with a single piece design, optimized vacuum system, and targeted vacuum channels, made from lightweight materials, which can be produced on-site, reducing material waste and improving flatness and vacuum efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing (CNC machining) is used to produce support blocks, then manufacturing precision and structural integrity are improved, but production time and cost increase significantly
Solution Approach 1:
The patent uses 3D printing to create a digital copy or replica of the support block structure, allowing rapid prototyping and production without traditional machining. This digital manufacturing approach maintains dimensional accuracy while dramatically reducing production time compared to CNC machining.
Solution Approach 2:
The invention changes the manufacturing parameter from subtractive (CNC machining) to additive (3D printing) process. This parameter change enables faster production while maintaining the required dimensional tolerances through precise control of the additive manufacturing process parameters.
2Strength
If aluminum material is used for support blocks, then strength and durability are improved, but weight increases causing ergonomic issues and higher shipping costs
Solution Approach 1:
The patent employs composite materials, specifically carbon fiber reinforced polymers or other high-strength-to-weight ratio materials, to replace traditional aluminum. This composite approach maintains the required structural strength while significantly reducing the weight of the support blocks, thereby improving ergonomics and reducing shipping costs.
3Adaptability or versatility
If two-piece support block design (top block and bottom block) is used, then adaptability to accommodate components is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the top block and bottom block into a single integrated support block structure. This unified design incorporates all necessary features for accommodating components while eliminating the complexity of assembling and aligning two separate pieces, thereby reducing manufacturing steps and overall device complexity.
Solution Approach 2:
The invention introduces internal cavities and recesses within the single support block structure to provide the adaptability previously achieved through multiple pieces. By utilizing the internal three-dimensional space, the design accommodates various components without requiring additional external blocks or complex assembly.
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 improved flatness, reduced weight, and efficient vacuum application, enhancing ergonomic safety and lowering shipping and production costs while allowing on-site manufacturing and recyclability.
Implementation Method 1
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.