Flexible Circuit Attachment Coating for Wear and Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Flex circuits are prone to damage and wear during assembly or use, leading to increased risks of electrical noise due to high-stress flexing and stress at mounting and connection points.
Innovation Solution
A flexible circuit with an extruded material bonded to its surface in a specific pattern, providing abrasion resistance and noise abatement. The extruded material is applied using a dispensing apparatus and cured onto the surface of the flexible flat cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flex circuits are used to replace wire harnesses for space savings and flexibility, then space utilization and flexibility are improved, but the risk of damage and wear during assembly or use increases
Solution Approach 1:
The patent applies a protective coating material to the surface of the flex circuit before assembly or use. This coating acts as a cushioning layer that absorbs wear and damage during handling and assembly operations, preventing direct contact between external objects and the vulnerable flex circuit surface. The coating is applied in advance to protect against anticipated mechanical stresses.
Solution Approach 2:
The patent creates a composite structure by bonding a protective coating material to the flex circuit substrate. This composite combines the flexibility and electrical properties of the original flex circuit with the enhanced mechanical durability and abrasion resistance of the coating material, achieving both space efficiency and improved reliability.
2Adaptability or versatility
If high-stress flexing is applied to the flex circuit during assembly or use, then adaptability and routing flexibility are improved, but electrical noise increases due to wear and deterioration
Solution Approach 1:
The protective coating is applied beforehand to cushion the flex circuit during high-stress flexing operations. This coating layer absorbs mechanical stresses and prevents direct wear on the conductive traces, thereby reducing the generation of electrical noise while still allowing the necessary routing flexibility.
Solution Approach 2:
The patent changes the surface properties of the flex circuit by applying a coating with different mechanical and electrical characteristics. This coating modifies the surface parameters to reduce wear and electrical noise generation while maintaining the overall flexibility and adaptability of the flex circuit for routing applications.
3Reliability
If mounting and connection points are created on the flex circuit, then electrical connections and structural support are improved, but stress concentration increases leading to wear and electrical noise
Solution Approach 1:
The protective coating creates a composite structure at mounting and connection points, distributing mechanical stresses across both the coating and the flex circuit substrate. This composite approach reduces stress concentration on the conductive traces while maintaining secure electrical connections and structural support.
Solution Approach 2:
The coating material changes the mechanical parameters at mounting and connection points by providing a compliant interface that reduces stress concentration. This parameter change allows for secure electrical connections while minimizing the generation of electrical noise through reduced mechanical wear on the conductive elements.
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 extruded material coating enhances the durability and reliability of flex circuits by reducing wear and electrical noise, while maintaining flexibility and allowing for precise pattern application for structural support and routing control.
Implementation Method 1
The extruded material may include a urethane acrylate oligomer and a photo-initiator compound, and the extruded material may be configured to bond to the flexible flat cable via a photopolymerization cure mechanism.
Data Source
AI summary
A wiring assembly including a flex circuit including a plastic laminate layer and a mount location configured to receive a fastener secured to a substrate. The wiring assembly further includes a flex circuit attachment feature, the flex circuit attachment feature including an extruded material bonded to the plastic laminate layer at the mount location.