Composite Flexible Wiring Board Welded Metal Block Joining

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Solution Overview

Problem

Existing methods for manufacturing flexible printed wiring boards often result in waste due to the rectangular shape of the boards, which does not efficiently utilize the substrate area, and there is a need for a method to join these boards effectively while maintaining structural integrity and conductivity.

Innovation Solution

A composite flexible printed wiring board is created by welding metal blocks fitted through holes in the conductor and insulating layers of two flexible printed wiring boards, allowing for the formation of irregularly shaped boards and reducing waste by aligning and joining the boards via laser or resistance welding, with a plating layer to prevent metal block displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If rectangular flexible printed wiring boards are manufactured using existing methods, then the manufacturing process is simple, but substrate area is wasted due to inability to form irregular shapes

Engineering Contradiction:

Improveboard shapeVSAvoidsubstrate waste

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The flexible printed wiring board is divided into multiple separate boards that are joined together through metal blocks. This segmentation allows each board to be manufactured in optimal rectangular shapes while the composite structure achieves the desired irregular overall shape, eliminating substrate waste.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Metal blocks are inserted into holes formed in the flexible printed wiring boards, creating a nested structure where the metal blocks are contained within the board structure. This enables precise positioning and strong joining between multiple boards while maintaining the flexibility of the overall assembly.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If multiple flexible printed wiring boards are joined together, then irregular shapes can be formed and substrate waste is reduced, but the joining process becomes complex

Engineering Contradiction:

Improveboard shapeVSAvoidjoining process

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

Traditional mechanical joining methods (screws, clips, adhesives) are replaced with welding technology to join metal blocks. This substitution simplifies the joining process by eliminating the need for complex mechanical assemblies while providing strong, reliable connections between multiple flexible printed wiring boards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The joining process utilizes changes in physical parameters (temperature, electrical current) during welding to create strong bonds between metal blocks. By controlling welding parameters such as heat input, current density, and welding time, the process achieves reliable joins without adding mechanical complexity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If metal blocks are welded to join flexible printed wiring boards, then strong connections are achieved, but heat input may affect the flexible substrate

Engineering Contradiction:

Improvejoint strengthVSAvoidsubstrate temperature

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

Welding is applied locally only to the metal blocks rather than the entire flexible printed wiring board. This localized approach concentrates heat input only where needed for joining, minimizing thermal effects on the flexible substrate while achieving strong connections at the joint locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The welding process is performed quickly to minimize the duration of heat input to the flexible substrate. By using rapid welding techniques, the metal blocks are joined before excessive heat can diffuse to and damage the flexible polymer layers, maintaining both joint strength and substrate integrity.

Inventive Principle:

Principle #21Skipping (Rushing through)

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 enables the production of irregularly shaped composite boards that minimize substrate waste and ensure strong, reliable connections, maintaining flexibility and conductivity while allowing for deformation and efficient heat dissipation.

Implementation Method 1

welding the first metal block and the second metal block such that the first flexible printed wiring board and the second flexible printed wiring board have a welded portion joining the first metal block and the second metal block

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10297937B2Composite flexible printed wiring board and method for manufacturing composite flexible printed wiring board

Publication Date: 2019.05.21 IBIDEN CO LTD

AI summary

A composite flexible printed wiring board includes a first flexible printed wiring board having an insulating layer, conductor layers and a first metal block fitted in a hole penetrating through the conductor layers and insulating layer, and a second flexible printed wiring board having an insulating layer, conductor layers and a second metal block fitted in a hole penetrating through the conductor layers and insulating layer. The first flexible printed wiring board and the second flexible printed wiring board have a welded portion formed by welding the first metal block and the second metal block and joining the first metal block and the second metal block such that the welded portion is joining the first flexible printed wiring board and the second flexible printed wiring board.