Flex-Rigid Wiring Board Length Extension via Cut Folding
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Solution Overview
Problem
Existing flex-rigid wiring boards face challenges in efficiently extending their length while maintaining electrical connectivity and structural integrity, particularly when subjected to stress or impact, due to limitations in flexible wiring board design and manufacturing methods.
Innovation Solution
A flex-rigid wiring board is created by integrating a flexible wiring board with a rigid wiring board, where the flexible board is extended in length by forming cuts and folding portions, and electrically connected to the rigid board using conductive layers and insulation layers, with shielding layers removed from folding sections to enhance bendability and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the flexible wiring board is extended by making cuts and folding portions, then the length of the flexible wiring board is increased, but the structural integrity and electrical connectivity may be compromised under stress or impact
Solution Approach 1:
The flexible wiring board is divided into multiple sections by creating cut portions that do not completely sever the board. These cut portions create folding sections that allow the board to be extended while maintaining continuity of the conductive layers through the folds, thus segmenting the structure to achieve extension while preserving electrical connectivity.
Solution Approach 2:
The patent applies beforehand cushioning by designing the folding portions with specific geometries and by providing insulation layers and protective structures at the fold locations. These features are built in advance to cushion and distribute stress during folding and under impact conditions, preventing damage to the conductive layers and maintaining structural integrity during extension operations.
2Ease of operation
If shielding layers are removed from folding sections to enhance bendability, then the ease of folding is improved, but electromagnetic shielding may be compromised
Solution Approach 1:
The patent applies local quality by selectively removing shielding layers only at specific folding sections where bendability is required, while maintaining shielding layers in other areas of the flexible wiring board. This localized modification allows the folding sections to be more compliant and easier to bend, while the remaining shielding layers continue to provide electromagnetic interference protection for the conductive traces.
3Productivity
If the flexible wiring board is extended by folding, then the production efficiency and material utilization are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the cut portions and folding sections during the manufacturing process, before the final assembly and use of the flexible wiring board. The conductive layers are patterned and the cuts are made in advance, allowing the folding geometry to be precisely controlled during manufacturing. This preliminary formation of folding structures simplifies the overall manufacturing process compared to attempting to create folds after assembly, thereby improving productivity while managing manufacturing complexity.
Data Source
AI summary
A method for manufacturing a flex-rigid wiring board, including preparing a flexible wiring board having a flexible base material and having a conductive layer over the flexible base material, making a cut in the flexible wiring board to form a cut portion, and folding at least one portion of the flexible wiring board using the cut portion to form one or more folding portions such that the flexible wiring board is extended in length, and connecting the flexible wiring board to a rigid wiring board including a rigid base material and having a conductive layer over the rigid base material.