Bendable Printed Circuit Board With Plated Wire Interconnect
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing use of multiple rigid printed circuit boards (PCBs) connected by wire harnesses or additional circuitry in applications like overhead LED lighting increases material and labor costs, complexity, and reduces reliability due to the need for complex optics to angle LEDs at different orientations.
Innovation Solution
A bendable printed circuit board is created by dividing a single PCB into sections with a weakened portion and connecting them with a plated wire, allowing for angular positioning without additional components, using methods like scoring, perforating, or drilling, and soldering techniques such as hot bar reflow or laser soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rigid PCBs are connected by wire harnesses or additional circuitry, then electrical connectivity between sections is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple rigid PCB sections into a single integrated PCB structure with a flexible intermediate section, eliminating the need for separate wire harnesses or additional circuitry to connect multiple boards. The flexible section acts as an integrated connector that maintains electrical connectivity while allowing angular positioning, thereby reducing overall system complexity.
Solution Approach 2:
The PCB is segmented into multiple sections: rigid sections for component mounting and a flexible intermediate section for angular positioning. This segmentation allows the board to be divided into functional zones with different mechanical properties, enabling both structural integrity and flexibility within a single integrated component.
2Reliability
If multiple rigid PCBs are used with additional circuitry, then electrical connectivity is maintained, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple PCB sections and connection circuitry into a single manufactured component. The flexible intermediate section includes integrated conductive traces that provide electrical connectivity, eliminating the need for separate wire harnesses and reducing assembly steps, thereby lowering manufacturing costs.
Solution Approach 2:
The flexible intermediate section is pre-manufactured with conductive traces and connection points during the PCB fabrication process. This preliminary integration of electrical connections into the board structure eliminates subsequent assembly steps for wire harness installation and circuitry connection, reducing labor costs and manufacturing complexity.
3Adaptability or versatility
If complex optics are used to angle LEDs at different orientations, then LED positioning is achieved, but device complexity and cost increase
Solution Approach 1:
The patent replaces static optical components with a dynamic flexible PCB section that can be angularly positioned to orient LEDs at different orientations. The flexibility of the intermediate section allows the LED array to be angled relative to the main PCB body, providing orientational versatility through mechanical flexibility rather than complex optical elements.
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
This approach reduces costs and complexity by allowing a single PCB to be angled, improving quality and reliability by eliminating the need for multiple PCBs and additional circuitry, while maintaining electrical connectivity.
Implementation Method 1
soldering the plated wire to the at least one solder pad on each of the sections
Data Source
AI summary
A bendable printed circuit board is provided. The bendable circuit board may include a circuit board having first and second sections and at least one plated wire that electrically connects and mechanically joins the first and second sections together. The first section may be pivotable with respect to the second section through the at least one plated wire.