Flexible Circuit Board Coupling for Rigid PCB Space Optimization
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Solution Overview
Problem
Rigid printed circuit boards in circuit breakers face space constraints due to connection requirements, leading to increased manufacturing time and costs, as well as reduced reliability and uncontrolled routing of connections, which complicates assembly and replacement.
Innovation Solution
Incorporating a flexible printed circuit board that couples rigid circuit boards, allowing them to be positioned in non-parallel orientations and freeing up space on the rigid board surfaces for electronic components, while eliminating the need for traditional jumper wires and solder connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid circuit boards are used with traditional connections (jumper wires and solder connections), then electrical connectivity between boards is achieved, but space on the main surface is drastically reduced and manufacturing time increases
Solution Approach 1:
The patent transitions from planar connections on the board surface to three-dimensional routing using flexible circuit boards that can route connections in multiple spatial dimensions, effectively moving connection paths off the main surface plane and into the vertical and lateral space around the rigid boards.
Solution Approach 2:
The flexible circuit board serves as an intermediary element between rigid circuit boards, providing a dedicated routing medium that separates connection functions from component mounting surfaces, thereby freeing up space on rigid boards while maintaining reliable electrical connections.
2Reliability
If traditional jumper wires and solder connections are used, then electrical connections are established, but manufacturing time and costs increase due to hand assembly requirements
Solution Approach 1:
The patent merges the connection routing function with the flexible circuit board structure itself, allowing multiple connections to be integrated into a single flexible board component that can be pre-assembled and then attached as one unit, eliminating the need for individual hand-assembly of jumper wires and solder connections.
Solution Approach 2:
The flexible circuit board allows connections to be pre-routed and pre-assembled before final installation, enabling manufacturing operations to be performed in an optimized sequence rather than requiring time-consuming hand assembly of individual connections during final assembly.
3Reliability
If individually routed connections are used between rigid circuit boards, then electrical connectivity is achieved, but routing locations become uncontrolled and disorganized
Solution Approach 1:
The flexible circuit board serves multiple functions simultaneously: it provides structured routing for multiple electrical connections, acts as a mechanical support structure, and enables controlled positioning of rigid boards in various orientations, thereby reducing overall assembly complexity while maintaining connection reliability.
Solution Approach 2:
The patent changes the physical state and properties of the connection medium from rigid and individually routed to flexible and collectively routed, allowing the connection system to adapt to different board orientations and positions while maintaining controlled and organized routing paths.
4Ease of manufacture
If rigid circuit boards are positioned in fixed orientations, then assembly is simplified, but adaptability to different mounting configurations is reduced
Solution Approach 1:
The flexible circuit board introduces dynamic adaptability to the circuit board assembly, allowing rigid boards to be positioned in different orientations (parallel or non-parallel) while the flexible board dynamically adjusts its routing configuration to maintain proper electrical connections, thereby providing both assembly ease and orientation flexibility.
Data Source
AI summary
A circuit breaker includes a housing, a rigid circuit board, and a flexible circuit board. The rigid circuit board is enclosed within the housing and has a main surface for supporting an electronic component. The flexible circuit board has a first end that is directly attached to an edge of the rigid circuit board.