Aluminum Flexible PCB Assembly for Lighter Modular Wire Harnesses
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Solution Overview
Problem
Existing copper core wire harnesses are cumbersome, time-consuming to organize and maintain, and costly due to their weight and complexity, making troubleshooting and repairs laborious.
Innovation Solution
An aluminum flexible printed circuit board assembly is developed, comprising a main circuit board with a flexible aluminum layer and insulating layers, connected to branch circuit boards, using connectors and pads with insulating sealants for secure bonding, facilitating easier assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If copper core wire harness is used, then electrical connection function is achieved, but weight and complexity increase
Solution Approach 1:
The wire harness is segmented into multiple flexible circuit boards (main circuit board and branch circuit boards) that can be independently configured and connected. This segmentation allows for reduced weight compared to traditional copper wire harnesses while maintaining electrical connection functionality through standardized connector interfaces.
Solution Approach 2:
The material parameter is changed from copper core to aluminum flexible circuit board material. This parameter change reduces the weight and complexity of the wire harness while maintaining the electrical connection function through the aluminum circuit layers and insulating layers.
2Ease of repair
If traditional copper wire harness is used, then electrical connection is established, but troubleshooting and repair time increases
Solution Approach 1:
The circuit system is divided into modular flexible circuit boards with standardized connectors. This segmentation enables easy identification and replacement of specific circuit board modules without needing to trace and replace entire wire harnesses, significantly reducing troubleshooting and repair time.
Solution Approach 2:
Standardized connectors and bonding pads are used across all circuit boards, creating universal interfaces that simplify the repair process. The same connector types and bonding methods are used throughout the system, making repair procedures consistent and time-efficient regardless of which specific circuit board needs replacement.
3Ease of manufacture
If copper wire harness is used, then electrical connection is achieved, but production cost increases
Solution Approach 1:
The material parameter is changed from copper to aluminum for the flexible circuit boards. Aluminum is generally less expensive than copper, and the standardized manufacturing process for flexible circuit boards with aluminum layers reduces production costs while maintaining electrical connection functionality.
Solution Approach 2:
Multiple circuit board functions are merged into a integrated flexible circuit board assembly with standardized connectors. This merging reduces the total quantity of materials needed compared to traditional wire harnesses and simplifies the manufacturing process through standardized production methods.
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 solution reduces production costs and overall weight, simplifies maintenance and repair processes, and provides a more flexible and efficient connection system compared to traditional copper core wire harnesses.
Implementation Method 1
The bonding pad is welded to the corresponding first bonding pad
Implementation Method 2
an insulating sealant is provided at the welding point
Data Source
AI summary
An aluminum flexible printed circuit board assembly and a preparation method. The aluminum flexible printed circuit board assembly comprises a first circuit board and a second circuit board, the main circuit board is a flexible printed circuit board, and the two end parts of the main circuit board are communicated with the first circuit board; the branch circuit boards are flexible printed circuit boards, one end parts of the plurality of branch circuit boards are respectively communicated with the surface of the main circuit board, and the other end parts of the plurality of branch circuit boards are respectively communicated with the second circuit board; the main circuit board is provided with a first aluminum circuit layer and a first insulating layer, and the branch circuit board is provided with a second aluminum circuit layer and a second insulating layer.