Component carrier for electrical/electronic components
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Solution Overview
Problem
Existing component carriers face assembly and operational issues due to thin conductor tracks bending or breaking when contacting heavy electrical components, leading to contact problems that are difficult to manage over time.
Innovation Solution
Designing conductor lugs for electric motors as multiple or double layers with a folded edge and connecting bridges, providing increased material thickness and stability, even in thin conductor track structures, to absorb mechanical stresses and prevent bending or breaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the material thickness of the conductor track structure is reduced to save cost, then manufacturing cost decreases, but mechanical strength and reliability deteriorate causing conductor lugs to bend or break during assembly and operation
Solution Approach 1:
The conductor track structure employs different thicknesses at different locations: thin material (cost-effective) in non-critical areas and multiple layers (high strength) specifically at conductor lugs that contact heavy electrical components like motors. This local differentiation resolves the contradiction by applying material thickness only where mechanically necessary.
Solution Approach 2:
The conductor track structure uses a composite construction with multiple layers of conductive material stacked and bonded together, particularly at conductor lugs. This creates a composite structure that provides both electrical conductivity and enhanced mechanical strength to prevent bending and breaking during assembly and operation.
2Loss of substance
If thin conductor tracks are used to reduce material consumption, then material cost decreases, but mechanical strength deteriorates leading to bending and breaking of conductor lugs
Solution Approach 1:
The design applies thin material in most areas to minimize consumption, but strategically places multiple layers at conductor lugs where mechanical strength is critical. This localized thickening ensures strength where needed while maintaining overall material efficiency.
Solution Approach 2:
Multiple layers of conductive material are bonded together to form a composite structure at conductor lugs, providing enhanced mechanical strength and resistance to bending and breaking while maintaining reasonable material consumption across the entire component carrier.
3Strength
If conductor lugs are made thicker to prevent bending and breaking, then mechanical strength improves, but material consumption and manufacturing cost increase
Solution Approach 1:
Instead of uniformly thickening the entire conductor track structure, the invention applies multiple layers only at specific locations where conductor lugs contact heavy electrical components. This localized approach provides necessary mechanical strength while avoiding unnecessary material consumption in other areas.
Data Source
Figure 1
Figure 2
AI summary
1. Component carrier for electrical/electronic components (1, 2, 3), for example for the combination with a lock housing (4) or as a component of a lock housing (4) of a motor vehicle door lock, comprising a carrier element (4) and a conductor track structure (6) of individual metallic conductor tracks (6'), which can be connected to the carrier element (4), wherein at least one conductor track (6') of the conductor track structure (6) comprises in some areas a multi-layer structure and, in particular, a double-layer structure (7).