Flat FPC Terminal Spot Welding for Connector-Free PCB Assembly
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Solution Overview
Problem
Conventional methods for connecting flexible printed circuits (FPCs) to printed circuit boards, such as the wire method and connector connection method, face challenges including high product costs and inefficient space layout, as well as cumbersome assembly processes.
Innovation Solution
A direct FPC connection structure using flat-plate FPC terminals coated with an insulating film, which are spot welded to substrate terminals on the printed circuit board, eliminating the need for connectors and allowing for a more cost-effective and efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector connection method is used to connect FPC to printed circuit board, then the assembling convenience is improved, but the product cost increases due to the addition of connector component and SMT process
Solution Approach 1:
The patent extracts and eliminates the connector component from the connection system. Instead of using a separate connector, the FPC terminal is directly welded to the substrate terminal unit, removing the unnecessary intermediary component while maintaining connection functionality.
Solution Approach 2:
The patent merges the FPC terminal connection structure with the substrate terminal unit by directly welding them together. This integration eliminates the separate connector component and simplifies the overall connection structure, reducing both part count and assembly complexity.
2Ease of manufacture
If the wire method is used to connect sensing wire to printed circuit board, then the assembling is excellent, but the product cost increases due to the addition of wire component
Solution Approach 1:
The patent extracts and removes the separate wire component from the connection system. The FPC terminal serves as the direct electrical connection element, eliminating the need for additional wire components while maintaining the ease of assembly through direct welding.
Solution Approach 2:
The FPC terminal is designed to perform multiple functions: it serves as both the electrical conductor and the connection element that is directly welded to the substrate terminal unit. This multi-functionality eliminates the need for separate wire components.
3Ease of operation
If the connector connection method is used, then the assembling convenience is improved, but the product cost increases due to the addition of surface-mount technology process
Solution Approach 1:
The patent replaces the mechanical connector insertion and latching system with a direct welding process. The FPC terminal is welded directly to the substrate terminal unit, eliminating the need for SMT processes and mechanical connector assembly while maintaining connection reliability.
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
The FPC connection structure enables direct bonding of FPCs to printed circuit boards without connectors, reducing costs and improving assembly efficiency by using a spot welding method, thus providing a more economical and convenient connection solution.
Implementation Method 1
each FPC terminal is a flat plate adapted to enable spot welding on a substrate terminal unit provided on the printed circuit board
Data Source
AI summary
An FPC connection structure including: several strands of FPC conductor patterns coated with an insulating film; and FPC terminals each extending from one end portion of each of the FPC conductor patterns and provided in a flat type to enable spot welding on a substrate terminal unit provided on the printed circuit board.