Flexible Printed Circuit Board With Compensating Folds
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Solution Overview
Problem
Current flexible electronic printed circuit boards face challenges in achieving high flexibility and longevity while maintaining simplicity in technology and materials, with existing solutions either being space-consuming or costly due to complex geometries and materials.
Innovation Solution
A flexible printed circuit board with a compensating fold attached to a non-elastic substrate using adhesive, allowing for a simple bendable topology and accommodating displacement, which can be supported by a modified bistable spring structure for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If special geometry and topology of the printed circuit board are applied at folding points, then flexibility is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The printed circuit board is divided into rigid sections connected by flexible fold lines. The board is segmented into multiple rigid panels (first rigid panel, second rigid panel, etc.) that are connected through flexible fold structures, allowing the board to bend while maintaining circuit integrity in each rigid section.
Solution Approach 2:
The printed circuit board transitions from a static rigid structure to a dynamic flexible structure by incorporating fold lines that allow controlled bending. The board can change its shape and configuration dynamically while maintaining electrical connectivity through the fold structures.
2Ease of operation
If meander shape is used to achieve flexibility, then flexibility is improved, but lifespan when bending deteriorates
Solution Approach 1:
The board is segmented into rigid panels connected by flexible folds, distributing bending stress away from the circuit traces. This segmentation prevents the meander pattern from being subjected to repeated flexing, thereby extending lifespan while maintaining flexibility.
Solution Approach 2:
The fold structure acts as an intermediary element between rigid panels, absorbing bending stresses and protecting the rigid circuit sections from direct mechanical stress. This intermediary fold structure allows flexibility without compromising the lifespan of the rigid circuit portions.
3Ease of operation
If elastic conductive materials are used, then flexibility and elasticity are improved, but cost increases
Solution Approach 1:
The board uses segmented rigid panels connected by flexible folds rather than using expensive elastic conductive materials throughout. This segmentation allows flexibility to be achieved through the fold geometry itself, eliminating the need for costly elastic materials in the conductive paths.
Solution Approach 2:
The invention replaces expensive elastic conductive materials with simple, inexpensive rigid circuit boards that have flexible fold structures. The solution uses basic rigid materials that are cheaper to manufacture while achieving flexibility through the fold geometry rather than through expensive elastic materials.
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
This solution increases the reliability and lifespan of the circuit board to over 100,000 cycles, enabling flexible and durable wearable devices with simple technology and materials.
Implementation Method 1
a flexible substrate to which the printed circuit board is fixed with two of its opposing end sides
Implementation Method 2
the printed circuit board has at least one fold or gather parallel to the end sides, which is formed as a raised bend from the substrate
Data Source
AI summary
The developed construction of the flexible circuit board is distinguished by the presence of compensating folds with a simple topology, which allow the circuit board to be installed in a flexible-hard body in such a way that the integrity of the circuit board is maintained when bending and rolling up, and the lifespan of the device during rolling/unrolling reaches 100,000 cycles and more.