Circuit Board Fixture for Flexible Circuit Assembly
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Solution Overview
Problem
Existing methods for assembling circuit boards with flexible circuits often result in damage due to excessive bending, stress, and misalignment, leading to inoperable assemblies and increased manufacturing costs.
Innovation Solution
A circuit board assembly fixture with supporting surfaces, hinges, fastening mechanisms, and retainers that allow for controlled alignment and structural support, reducing the risk of damage and misalignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flexible circuit portions are bent to a tight radius to conform to specific shapes, then the circuit board can achieve desired configuration, but the flexible circuit portion may be pinched or broken
Solution Approach 1:
The patent applies preliminary action by pre-forming the flexible circuit portions with appropriate bend radii during manufacturing, and by using pre-configured fixtures with predetermined geometry that guide the bending process before assembly. This ensures circuits are not subjected to improper tight bending during assembly operations.
Solution Approach 2:
The patent introduces intermediary fixtures and jigs with specifically designed geometries that act as mediators between the flexible circuits and the final assembled shape. These intermediaries provide controlled bending paths with adequate radii, preventing direct tight bending that would damage the circuits while still achieving the desired configuration.
2Shape
If flexible circuits are bent during assembly to achieve desired shape, then the circuit board can conform to specific configurations, but undesirable stresses are induced on the circuit board assembly
Solution Approach 1:
The patent performs shape conformation as a preliminary action before final assembly, using fixtures that gradually guide the flexible circuits into their final configuration. This preliminary forming eliminates the need for stress-inducing bending during the assembly process itself, as the circuits are already in their desired shape when components are attached.
Solution Approach 2:
The patent employs intermediary fixtures with controlled geometry that mediate the bending process, distributing stresses evenly and preventing concentration of forces on the flexible circuits. These intermediaries provide controlled deformation paths that minimize stress while achieving the required configuration.
3Shape
If multiple assembly steps with jigs are used to align and shape circuit boards, then the desired configuration can be achieved, but assembly time and complexity increase
Solution Approach 1:
The patent merges multiple assembly functions into a single integrated fixture that simultaneously provides alignment, bending guidance, and component positioning. This consolidation eliminates the need for sequential operations with multiple jigs, reducing assembly time while maintaining configuration accuracy.
Solution Approach 2:
The patent designs universal fixtures that perform multiple functions: they align circuit boards, guide flexible circuit bending with proper radii, position components, and maintain configuration throughout assembly. This multi-functionality replaces several specialized jigs with a single tool, reducing complexity and time.
4Shape
If flexible circuits are bent during assembly, then the circuit board can achieve desired shape, but misalignment in final assembly increases
Solution Approach 1:
The patent performs alignment as a preliminary action using fixtures with precision-machined reference surfaces and alignment features. Circuits are aligned and secured in their final configuration before any bending or component attachment occurs, ensuring that subsequent operations do not disrupt the precise alignment.
Solution Approach 2:
The patent introduces intermediary alignment fixtures and reference features that mediate between the flexible circuits and the final assembly configuration. These intermediaries provide stable, precise reference geometries that maintain alignment during the bending process, preventing misalignment that would occur with direct manipulation.
Data Source
AI summary
A method of assembling a circuit board assembly is provided. The circuit board assembly includes a circuit board assembly fixture and a plurality of fixed circuits. The method includes coupling the plurality of fixed circuits to the circuit board assembly fixture. The plurality of fixed circuits includes at least one of a fully flexible circuit, a flexible circuit having stiffeners, and a rigid circuit. The fixture includes a plurality of supporting surfaces each including a first side, configured to receive at least one of the fixed circuits, and an opposite second side. The fixture includes at least one hinge, at least one fastening mechanism extending from the first side, and at least one retainer coupled to at least one of the plurality of supporting surfaces. The method includes folding the circuit board assembly fixture into a desired alignment.