Selective Coating Patterns for Wear-Resistant Flex Circuits
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Solution Overview
Problem
Flexible circuits are prone to damage and wear during assembly and use, leading to increased risks of electrical noise due to high-stress flexing and stress at mounting points, which affects their reliability and performance.
Innovation Solution
A flexible circuit with an extruded material coating, such as a urethane acrylate oligomer, is applied in specific patterns to provide abrasion resistance and noise abatement, using methods like FDM, 3D printing, or aerosolization, which is cured to create structural features that enhance durability and stiffness.
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 wear resistance and durability deteriorate due to high-stress flexing and contact during assembly
Solution Approach 1:
The patent applies coating material selectively to specific high-wear areas of the flex circuit (such as contact points, mounting regions, and high-stress flex zones) rather than uniformly across the entire circuit. This localized application provides enhanced durability precisely where needed while preserving the overall flexibility and space advantages of the flex circuit design.
Solution Approach 2:
The patent uses composite coating materials applied to the flex circuit substrate. These coatings (such as polyurethane, polyester, or other protective polymers) create a composite structure that combines the flexibility of the base flex circuit with the enhanced wear and abrasion resistance of the coating layer, thereby improving reliability without sacrificing flexibility.
2Reliability
If coating material is applied to high-wear areas of the flex circuit, then wear resistance is improved, but manufacturing complexity increases due to selective pattern application requirements
Solution Approach 1:
The patent employs masking techniques where the flex circuit itself or attached masks define the coating pattern. The masking process allows the coating material to be applied selectively to high-wear areas through self-alignment and automated dispensing, reducing the need for complex manual positioning and minimizing manufacturing complexity while achieving precise pattern application.
3Reliability
If structural coating is applied to prevent kinking and pinching, then durability is improved, but flexibility may be reduced due to added stiffness
Solution Approach 1:
The patent applies structural coating material selectively to specific regions of the flex circuit (such as mounting points, connection areas, and high-stress zones) rather than uniformly across the entire circuit. This localized reinforcement provides necessary structural support and protection against kinking and pinching while preserving the flexibility of the uncoated portions, thereby maintaining adaptability.
Solution Approach 2:
The patent uses thin-film coating materials that provide structural reinforcement while maintaining flexibility. These coating layers are designed to be thin enough to allow the flex circuit to bend and flex as needed, yet sufficiently robust to prevent kinking and pinching, thus preserving adaptability while improving durability.
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 solution significantly reduces wear and electrical noise by providing structural support and abrasion resistance, maintaining flexibility while preventing kinking or pinching, and minimizing squeak and rattle in applications like automotive wiring assemblies.
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
Implementation Method 2
aerosolizing a material comprising a urethane acrylate oligomer and a photo-initiator compound
Implementation Method 3
projecting the material on the flex circuit
Data Source
AI summary
A method of forming a flexible circuit, including providing a flexible flat cable with a first surface and a second surface. The first surface of the flexible flat cable is diametrically opposed to the second surface. A dispensing apparatus including a nozzle is further provided, and an extruded material is dispensed through the nozzle onto the first surface of the flexible flat cable. The extruded material is shaped into a pattern and cured onto the first surface of the flexible flat cable.