Flexible Circuit Power Supply Assembly for Wire-Free LED Connection
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Solution Overview
Problem
Existing power supply assemblies face challenges in efficiently connecting LED indicators and fans due to the use of flying wires, which occupy space, are prone to damage, and hinder automated assembly, leading to inefficient space utilization and manual assembly processes.
Innovation Solution
Implementing a flexible circuit board to electrically connect LED indicators and fans, arranged under the main circuit board, which avoids occupying space and allows for automated assembly by using a positioning base and insulator design to simplify the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flying wires are used to connect LED indicator and fan to the main circuit board, then electrical connection can be achieved, but the flying wires occupy space above the main circuit board and cannot be assembled automatically
Solution Approach 1:
The patent uses a flexible circuit board (thin film structure) to replace the traditional flying wire connection. The flexible circuit board is disposed below the main circuit board and extends to connect with the LED indicator and fan, providing reliable electrical connection while enabling automated assembly through its rigid-flex structure that can be pre-assembled with positioning features.
Solution Approach 2:
The patent relocates the connection structure from the vertical dimension (flying wires extending upward from the main circuit board) to the horizontal dimension (flexible circuit board extending laterally below the main circuit board). This dimensional change eliminates the need for manual wire arrangement and enables automated assembly while maintaining electrical connectivity.
2Ease of manufacture
If flying wires are used for electrical connection, then the LED indicator and fan can be connected to the power supply unit, but the flying wires must be manually arranged and inserted into connection terminals
Solution Approach 1:
The flexible circuit board replaces manual wire arrangement with a pre-fabricated rigid-flex circuit structure that includes built-in connection terminals. This structure can be automatically positioned and connected to the LED indicator and fan, eliminating the need for manual wire insertion while maintaining manufacturing simplicity.
Solution Approach 2:
The flexible circuit board is pre-assembled with the LED indicator and fan before being installed with the main circuit board. The positioning base and positioning posts are pre-configured to ensure automatic alignment during final assembly, reducing the complexity of the assembly process.
3Area of stationary object
If the flexible circuit board is arranged under the main circuit board, then space utilization is improved, but the elastic conductor needs support to maintain proper positioning
Solution Approach 1:
The support structure is segmented into modular components: positioning base attached to the housing, positioning posts extending from the positioning base, and reinforcing plates integrated with the flexible circuit board. This segmentation allows each component to perform its specific function while maintaining overall simplicity and enabling automated assembly.
Solution Approach 2:
The positioning posts act as intermediaries between the positioning base and the flexible circuit board, providing mechanical support and precise positioning. The reinforcing plates serve as intermediaries between the elastic conductor and the positioning structure, ensuring proper alignment and electrical contact.
4Reliability
If the protruding height of the elastic conductor is increased to improve connection reliability, then the connection between the conductive pad and elastic conductor is more reliable, but the installation gap becomes smaller
Solution Approach 1:
The patent optimizes the protruding height parameter of the elastic conductor to achieve the best balance between connection reliability and installation gap. The positioning posts and reinforcing plates provide precise control over the protruding height, ensuring reliable electrical contact while maintaining adequate installation clearance.
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 flexible circuit board simplifies the assembly structure, improves space utilization, and enables automated assembly by eliminating the need for flying wires, ensuring reliable electrical connections and efficient component placement.
Implementation Method 1
the elastic conductor and the conductive pad are abutted against each other, so that the LED indicator and the main circuit board are electrically connected to each other
Data Source
AI summary
A power supply assembly is provided and includes a housing, a flexible circuit board, an insulator and a circuit board assembly. The housing includes a positioning base disposed on a carrying surface. The flexible circuit board is disposed on the carrying surface, extended from a first end side of the housing to the positioning base, and including a LED indicator adjacent to the first end side and an elastic conductor located on the positioning base. The flexible circuit board is sandwiched between the carrying surface and the insulator, and the elastic conductor protrudes through the insulator. The circuit board assembly includes a main circuit board having a conductive pad corresponding to the elastic conductor. The circuit board assembly is assembled to the insulator, the conductive pad is close to the insulator and abutted against the elastic conductor, so that the LED indicator and the main circuit board are electrically connected.