Curved Flexible PCB for 3D Circuit Assembly
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Solution Overview
Problem
Current methods for producing three-dimensional electronic circuits require electronic boards to be fabricated flat and components to be soldered in a flat position, necessitating the use of connectors for closing the circuit, which complicates the production process.
Innovation Solution
The use of curved flexible printed circuits that can be folded to link opposing ends of electronic boards, allowing the circuit to be erected into a volume without additional soldering or assembly elements, enabling the production of a three-dimensional circuit entirely in a flat state and then folded into a volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If connectors are used to close the circuit in three-dimensional configuration, then the circuit can be formed in 3D, but the production process becomes more complex
Solution Approach 1:
The circuit is divided into multiple planar segments or layers that are folded along predetermined hinge lines. Each segment can be independently fabricated in a flat state using standard PCB processes, then assembled into a three-dimensional configuration through folding, eliminating the need for complex 3D fabrication and connectors.
Solution Approach 2:
The invention transitions from a purely planar two-dimensional circuit layout to a three-dimensional structure by introducing folding along hinge lines. This allows the circuit to occupy three-dimensional space while maintaining planar fabrication processes, as the 3D configuration is achieved through spatial transformation rather than complex 3D manufacturing.
2Ease of manufacture
If electronic boards are fabricated flat and components soldered flat, then manufacturing is simplified, but additional connectors and assembly elements are required to close the circuit in 3D
Solution Approach 1:
The invention merges the functions of the circuit traces and the mechanical folding structure into a single integrated flexible printed circuit board. The hinge lines are incorporated directly into the PCB design, combining the electrical connection function with the mechanical articulation function, thereby eliminating the need for separate connectors and assembly elements.
Solution Approach 2:
The flexible printed circuit board incorporates curved or bent traces and hinge regions that allow the board to fold into three-dimensional configurations. The curved design of the hinge lines enables smooth folding transitions while maintaining electrical connectivity, allowing the circuit to achieve 3D shapes without requiring additional rigid connectors.
3Shape
If connectors and assembly elements are used to close the circuit, then three-dimensional configuration is achieved, but production complexity increases
Solution Approach 1:
The hinge lines and fold patterns are pre-designed and pre-fabricated into the PCB during the standard manufacturing process. The circuit board is prepared in advance with predetermined folding zones that guide the assembly process, allowing for rapid and accurate formation of three-dimensional configurations without requiring complex real-time assembly operations or additional connectors.
Data Source
AI summary
This electronic circuit, includes a set of electronic boards intended to support components and linked together by joining elements. The joining elements include curved flexible printed circuits linking two opposing ends of two electronic boards running side by side, the said curved flexible printed circuits being foldable for erecting the electronic circuit into a volume so that the electronic circuit comprises electronic boards placed opposite one another.