Embedded Double-Helix Fuse Layout for Compact FPCBs

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Solution Overview

Problem

Flexible printed circuit boards (FPCBs) face increased volume and costs due to the need for separate fuse mounting, which complicates their manufacturing process and assembly.

Innovation Solution

Incorporating a pattern fuse with a double helix structure directly into the FPCB's pattern circuit layer, eliminating the need for external fuse mounting by using a through polymer via (TPV) method, which reduces volume and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fuse is mounted separately on the FPCB through a mounting process, then the FPCB can provide protection function, but the total volume of the FPCB increases and costs increase

Engineering Contradiction:

Improveprotection functionVSAvoidtotal volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines the fuse function directly into the pattern circuit layer by forming a pattern fuse through etching the copper foil. This merging eliminates the need for separate fuse mounting, thereby reducing the total volume while maintaining the protection function. The pattern fuse is integrated as part of the circuit board structure itself rather than being a separate component.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a fuse is mounted separately on the FPCB through a mounting process, then the FPCB can provide protection function, but costs increase

Engineering Contradiction:

Improveprotection functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fuse function is merged into the pattern circuit layer formation process. The pattern fuse is created by etching the copper foil during the standard PCB manufacturing process, eliminating the need for separate fuse components and mounting operations. This integration reduces manufacturing complexity and costs while maintaining the protection function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pattern circuit layer itself serves the dual purpose of providing electrical connectivity and fuse protection. The copper foil pattern automatically provides the fuse function when etched appropriately, eliminating the need for external fuse components. The structure serves itself by incorporating the protection function into its basic circuitry.

Inventive Principle:

Principle #25Self-service

3Reliability

If a fuse is mounted separately on the FPCB, then the FPCB can provide protection function, but the manufacturing process becomes complicated

Engineering Contradiction:

Improveprotection functionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The fuse formation is merged with the pattern circuit layer formation. Both the pattern fuse and the circuit patterns are created simultaneously through the same etching process of the copper foil. This eliminates separate mounting steps and reduces manufacturing process complexity while maintaining the protection function.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4132232B1FPCB and manufacturing method therefor

Publication Date: 2024.12.25 LG ENERGY SOLUTION LTD

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AI summary

In an FPCB comprising a pattern circuit layer according to an embodiment of the present invention for achieving the above objects, the pattern circuit layer has a pattern fuse embedded therein, and the pattern fuse includes: a first conductive wire made of a metal and having a spiral structure; and a second conductive wire made of a metal and having a spiral structure, wherein the first conductive wire and the second conductive wire have a double helix structure.