Circuit Substrate Ground Wiring Positioning for Crack Suppression
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Solution Overview
Problem
Circuit substrates used in bent forms for power steering apparatuses are prone to minute cracks near flexible and rigid part boundaries, leading to insulating failures and wiring disconnections due to moisture infiltration.
Innovation Solution
A circuit substrate design with a flexible part having a ground wiring positioned on its outer side, closer to the side edges than the inter-component-mounting-part wirings, to suppress crack occurrence and prevent insulating failures and disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible parts are used to enable bending of the circuit substrate, then adaptability and ease of installation are improved, but cracks occur near the boundaries between flexible and rigid parts leading to insulating failure and wiring disconnection
Solution Approach 1:
The patent applies local quality by positioning ground wirings specifically at the boundaries between flexible and rigid parts where cracks are most likely to occur. This localized reinforcement provides targeted protection without requiring changes to the entire substrate structure, allowing the flexible parts to maintain their bending capability while specific critical areas gain enhanced crack resistance.
Solution Approach 2:
The ground wirings act as an intermediary protective layer between the flexible and rigid parts. This intermediary structure absorbs and distributes stress at the boundary interface, preventing crack propagation into the signal and power source wirings. The ground wiring layer serves as a mechanical buffer that maintains electrical integrity while accommodating the differential movement between flexible and rigid sections.
2Reliability
If ground wirings are positioned closer to the side edges of the flexible part, then crack suppression and insulating failure prevention are improved, but wiring layout complexity increases
Solution Approach 1:
The ground wirings serve multiple functions simultaneously: they provide electrical grounding, act as a mechanical reinforcement layer to suppress cracks, and serve as a stress-distribution structure at the flexible-rigid boundaries. This multi-functionality allows the same wiring structure to address both electrical and mechanical reliability concerns without requiring additional separate protective structures.
Solution Approach 2:
The patent implements local quality by concentrating ground wirings specifically at the critical boundary regions between flexible and rigid parts, rather than uniformly distributing them across the entire substrate. This localized approach provides maximum crack suppression where it is most needed while minimizing the overall wiring complexity and material usage.
Data Source
AI summary
A circuit substrate (3) is provided with first and second rigid parts (11, 12) having six metal foil layers, and a thin flexible part (13) having two metal foil layers connecting the two rigid parts. A ground wiring (51) which is shaped like a wide strip is formed on the surface metal foil layer, and a plurality of inter-rigid-part wirings (55) are formed on the inner metal foil layer in parallel lines. Outer edges (51a) of the ground wiring (51) are positioned closer to side edges (13a) of the flexible part (13) than to the inter-rigid-part wirings (55). The ground wiring (51) protects the inter-rigid-part wirings (55) from cracks.


