Busbar Module Layout Using Deformed FPC Branch Connections
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Solution Overview
Problem
Conventional techniques for connecting a flexible printed circuit board to a busbar result in yield deterioration due to the need for a long flat plate-like portion extending in the width direction, leading to inefficiencies in manufacturing.
Innovation Solution
A busbar module and manufacturing method that involves cutting the branch portion of the flexible printed circuit board into a shape with a base end connected to the trunk portion and a piece portion extending in the longitudinal direction, then deforming this piece portion to extend in the width direction, allowing it to be connected to the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flat plate-like portion extends in the width direction to connect the trunk portion to the busbar, then the connection is achieved, but the manufacturing yield deteriorates
Solution Approach 1:
The branch portion is configured to extend primarily in the longitudinal direction rather than the width direction. By changing the orientation from width-direction extension to longitudinal-direction extension, the patent avoids the yield deterioration associated with wide flat plate portions while still achieving the necessary connection to the busbar through deformation of the piece portion.
Solution Approach 2:
The branch portion is divided into a base end connected to the trunk portion and a piece portion that can be deformed. This segmentation allows the circuit board to have a compact initial shape for high-yield manufacturing, while the deformable piece portion provides the flexibility needed for connection without requiring a large flat plate-like structure.
2Productivity
If the branch portion extends in the width direction to connect to the busbar, then the connection distance is covered, but the circuit board width increases reducing production efficiency
Solution Approach 1:
The patent changes the extension direction from width direction to longitudinal direction for the piece portion. This dimensional change allows the circuit board to maintain a narrow width suitable for high-density production while still achieving the required connection length through longitudinal extension and subsequent deformation.
Solution Approach 2:
The patent changes the physical state of the piece portion from rigid to deformable, allowing it to transition from a compact longitudinal configuration during manufacturing to an extended width-direction configuration during assembly. This parameter change enables small initial dimensions for high productivity while achieving large final dimensions for proper connection.
3Ease of manufacture
If a long flat plate-like portion is used to connect the trunk portion to the busbar, then the connection is established, but the manufacturing cost increases
Solution Approach 1:
The branch portion is segmented into a base end and a deformable piece portion. This segmentation allows the majority of the connection function to be achieved through deformation of a small piece portion rather than manufacturing a long flat plate-like structure, significantly reducing material usage and manufacturing cost.
Solution Approach 2:
The piece portion is used in a deformed state to achieve connection, effectively 'discarding' its original longitudinal shape and 'recovering' a new functional shape that provides the necessary connection without requiring a long initial structure, thereby reducing material waste and cost.
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 improves manufacturing efficiency and reduces costs by minimizing the width of the flexible printed circuit board, enabling more boards to be produced from a single substrate and enhancing component mounting efficiency.
Implementation Method 1
the branch portion is cut into a shape having a base end connected to the trunk portion and a piece portion extending from the base end in the longitudinal direction, and the branch portion is connected to the busbar in a state where the piece portion is deformed so as to extend in the width direction
Data Source
AI summary
A busbar module includes: a flexible printed circuit board including a trunk portion having a longitudinal direction and a width direction and a branch portion connected to an edge of the trunk portion in the width direction; a busbar connected to the branch portion of the flexible printed circuit board; and a case that accommodates the flexible printed circuit board and the busbar. The branch portion is cut into a shape having: a base end connected to the trunk portion; and a piece portion extending from the base end in the longitudinal direction. The branch portion is connected to the busbar in a state where the piece portion is deformed so as to extend in the width direction.