Flexible Circuit Alignment Using Sacrificial Section
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Solution Overview
Problem
As electronic modules decrease in size, the use of alignment pins for flexible circuit interconnects becomes impractical due to limited space, requiring precise alignment within tight tolerances without the use of pins on the module.
Innovation Solution
A method and apparatus that utilize a sacrificial section on the flexible circuit with alignment features to align with a tooling apparatus, allowing for precise attachment to a module without the need for alignment pins on the module, using an alignment apparatus with pins and blocking bars to secure the flexible circuit in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment pins are used on the module to position flexible circuits, then alignment precision is improved, but module size increases due to space requirements for pins
Solution Approach 1:
The patent moves the alignment features from the module (two-dimensional surface) to the flexible circuit itself (adding a third dimension through the sacrificial section). Alignment pins are eliminated by creating alignment structures that extend from the flexible circuit substrate, allowing alignment without occupying module surface real estate.
Solution Approach 2:
The sacrificial section acts as an intermediary element between the flexible circuit and the module. It provides alignment features that facilitate precise positioning during assembly, then is removed after serving its purpose, leaving no permanent occupation of module space.
2Volume of moving object
If module size is reduced to improve compactness, then space savings are achieved, but alignment precision deteriorates due to insufficient room for alignment pins
Solution Approach 1:
By transferring alignment features to the flexible circuit substrate and using protruding structures from the sacrificial section, the patent achieves precise alignment in compact modules without requiring traditional pin structures on the module itself.
Solution Approach 2:
The sacrificial section is prepared in advance with alignment features before assembly. This preliminary preparation ensures that alignment capability is built into the flexible circuit itself, eliminating the need for post-assembly alignment adjustments in compact modules.
3Volume of moving object
If alignment pins are made small to fit limited real estate, then module size is reduced, but ease of operation deteriorates as pins become too small for hand assembly
Solution Approach 1:
The sacrificial section serves as a temporary intermediary that provides large, easy-to-handle alignment features during assembly. After serving its alignment purpose, it is removed, leaving the final compact module design without the bulk of permanent alignment pins.
Solution Approach 2:
The sacrificial section is a temporary, disposable element used only during the assembly process. It provides the necessary alignment functionality for hand assembly with large, easy-to-grab features, then is discarded after its purpose is fulfilled, allowing the final product to be compact.
Data Source
AI summary
A method and apparatus for aligning components on a module are disclosed. A flexible circuit may be attached to a module in which a tooling apparatus is attached to the module. A plurality of circuit pads on a functional section of the flexible circuit is aligned by a first alignment structure located on a sacrificial portion of the flexible circuit to a second alignment structure on the tooling apparatus. The flexible circuit is attached to the module while the flexible circuit is in an aligned position.