Conductive Ink Interconnected Devices for Cable-Free Assembly
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Solution Overview
Problem
Cable management in device assemblies is inefficient, leading to increased costs, delays in manufacturing and setup, and difficulties in servicing components due to physical space limitations and the need for traditional cable connections.
Innovation Solution
The use of 3D printed nanoparticle conductive ink wires that connect PCB surface mount conductive pads to new external port locations on the device housing, eliminating the need for traditional cables, cable harnesses, and port connectors by establishing a wired connection through spring-based bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cables, cable harnesses, and port connectors are used for connecting peripheral devices to host devices, then reliable wired connections can be established, but manufacturing time increases by 5-8 weeks and overall system costs increase
Solution Approach 1:
The patent extracts and eliminates the cable, cable harness, and port connector components from the traditional connection system. By removing these intermediate elements, the invention directly connects the host device PCB to the peripheral device PCB through integrated circuit board traces, thereby reducing manufacturing time while maintaining connection reliability through the direct electrical pathway.
Solution Approach 2:
The patent merges the functions of multiple separate components (cable, connectors, cable harnesses) into a single integrated circuit board design. The host device and peripheral device are combined into one unified system where electrical connections are established through PCB traces rather than external cabling, eliminating the need for separate connection components and reducing assembly time.
2Ease of operation
If traditional cable management components are included in device assemblies, then cable organization and protection are achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent removes cable management components (cables, harnesses, connectors) from the device assembly entirely. By extracting these elements, the invention eliminates the need for cable routing channels, connector mounting structures, and harness management features, thereby reducing device complexity while maintaining operational simplicity through direct PCB-to-PCB connections.
Solution Approach 2:
The patent combines the cable management function into the circuit board design itself. The electrical connection pathway is integrated directly into the PCB structure, eliminating the need for separate cable management subsystems. This merging of functions reduces the overall number of components and simplifies the device architecture.
3Adaptability or versatility
If traditional port connectors are used on device housings, then external peripheral connections are enabled, but the housing design flexibility is reduced and servicing difficulty increases
Solution Approach 1:
The patent extracts the port connectors from the device housing and eliminates the need for external connection interfaces. By removing these physical ports from the housing design, the invention allows for greater housing flexibility and simplifies servicing, as connections are made through internal PCB traces that can be accessed directly without disassembling housing components or managing external connectors.
Solution Approach 2:
The patent merges the connection capability into the internal circuit board architecture rather than requiring external housing ports. The electrical connectivity is integrated into the PCB design, allowing the housing to be designed without dedicated connector openings or cable access points, thereby improving housing design flexibility and ease of repair.
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 solution reduces setup and manufacturing time, eliminates waste associated with traditional cabling, and simplifies the connection process between host devices and peripherals, thereby enhancing efficiency and reducing costs.
Implementation Method 1
3D printed nanoparticle conductive ink wires that connect PCB surface mount conductive pads to new external port locations on the device housing
Data Source
AI summary
A host device includes surface mount conductive pads on a printed circuit board (PCB) for external peripheral communications. Conductive ink is printed on the conductive pads with a base member is printed over the conductive ink. Three-dimensional (3D) conductive wires are printed on the base member and extend along a housing to a new external port. Conductive ink is printed with a second base member and terminating ends of the wires are printed on the front of the base member establishing the new peripheral port for the host device. A peripheral device includes its own surface mount conductive pads which when aligned and brought into contact with the external port of the host device permits the host device and the peripheral device to establish a wired connection with one another without cables, without cable harnesses, and without port connectors.