Flexible Circuit Waveform Shaping for Tear-Resistant Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for processing flexible circuits (FCs) in electrified vehicles, such as forming full-thickness slits in insulation material, lead to tearing and damage over time due to repetitive routing and attachment.
Innovation Solution
A system and method using a non-conductive tool with conductive heating elements to shape FCs without removing any portion of the FC, allowing for increased flexibility or rigidity by forming waveform shapes such as triangular or sinusoidal patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If full-thickness slits are formed in insulation material to increase flexibility, then routing flexibility is improved, but the FC tends to tear further than intended over time
Solution Approach 1:
The patent applies local quality by forming localized folds at specific positions along the FC rather than creating full-thickness slits throughout. The folds are concentrated at predetermined positions where flexibility is needed, while the rest of the FC maintains its structural integrity. This localized approach allows routing flexibility at critical points without compromising overall structural strength.
Solution Approach 2:
The patent segments the insulation layer by creating discrete folds at specific intervals rather than continuous slits. The conductor traces remain continuous while the insulation is folded at predetermined positions, dividing the flexibility enhancement into discrete segments that maintain overall structural coherence and prevent catastrophic tearing.
2Ease of operation
If conductive circuit traces are fully singulated to improve routing, then routing flexibility is improved, but the traces can be damaged especially over time after repetitive routing
Solution Approach 1:
The patent applies local quality by folding only the insulation layer at predetermined positions while leaving the conductor traces continuous and intact. This localized folding approach provides routing flexibility without singulating or damaging the conductive traces, maintaining their structural integrity even after repetitive routing operations.
3Adaptability or versatility
If conventional FC processing methods are used to increase flexibility, then routing capability is improved, but the FC suffers from tearing and damage over time
Solution Approach 1:
The patent applies preliminary action by pre-forming folds in the insulation layer at predetermined positions before the FC is installed. This preliminary shaping allows the FC to be easily routed and attached in compact environments while maintaining durability, as the folds are created in a controlled manner that prevents tearing and damage during subsequent handling and installation.
Solution Approach 2:
The patent changes the physical parameter of the insulation layer by folding it at predetermined positions to create permanent bends. This parameter change (from flat to folded) increases routing capability while the controlled folding process maintains material integrity, preventing the tearing and damage associated with conventional slit-based methods.
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 effectively enhances the flexibility or rigidity of FCs without causing permanent damage, allowing for improved routing and attachment in compact environments like electrified vehicle electrical systems.
Implementation Method 1
a power source configured to provide power to the conductive heating elements causing the conductive heating elements to generate heat energy
Data Source
AI summary
A system and method for shaping a flexible circuit (FC) having a set of conductive traces disposed within a set of insulation layers and a shaped FC, each involve using a non-conductive tool defining complimentary first and second tool portions and a shape therebetween, the tool being configured to receive a portion of the FC therebetween the first and second tool portions, a set of conductive heating elements arranged substantially in parallel with each other and disposed within the first and second tool portions, and a power source configured to provide power to the conductive heating elements causing the conductive heating elements to generate heat energy to shape the FC portion without removing any of the FC portion.