Flexible Printed Circuit Contact Geometry Optimization
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Solution Overview
Problem
Current methods for manufacturing flexible printed circuits for smartcards are costly and do not fully meet the design requirements for electrical contacts, particularly in terms of geometry and surface area optimization.
Innovation Solution
A method involving a rolled band of flexible material divided into zones, where each zone undergoes metallization to form optimized rectangular electrical contacts connected to a common frame, with specific dimensions and geometry tailored to reduce surface area and ensure reliable adhesion and conductivity, using a reel-to-reel system and electro-deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods are used for flexible printed circuits, then the contacts can be formed, but the manufacturing cost is high and the contact geometry does not fully meet design requirements
Solution Approach 1:
The patent applies parameter changes by optimizing the contact geometry with specific dimensions (2mm x 1.7mm rectangle) and controlling the summed surface area to be less than 127.01 mm². The metallization process parameters are adjusted to achieve the optimized contact shape that meets both cost and precision requirements.
Solution Approach 2:
The flexible band is divided into multiple zones, with each zone containing a specific number of electrical contacts (at least five per zone). This segmentation allows for standardized manufacturing of contact patterns that can be consistently reproduced across the entire band, reducing manufacturing cost while maintaining geometric precision.
2Ease of manufacture
If the contact surface area is reduced to meet design requirements, then the manufacturing cost decreases, but the adhesion and conductivity may be compromised
Solution Approach 1:
The patent optimizes the contact parameters by defining specific dimensional requirements (2mm x 1.7mm rectangle) and controlling the total surface area to be less than 127.01 mm². These parameter changes achieve cost reduction while maintaining reliable adhesion and conductivity through the optimized geometry that balances surface area with electrical performance.
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 method reduces manufacturing costs while ensuring good adhesion, conductivity, and longevity of the contacts, meeting the requirements for smartcard applications with optimized contact geometry and surface area.
Implementation Method 1
a reel-to-reel system and electro-deposition process
Data Source
Figure 1~4b
Figure 3a
Figure 4a~5
AI summary
A method of manufacture of flexible printed circuits having electrical contacts comprises: providing a rolled band (5) of a flexible material, unrolling the band so that zones are moved the one(s) after the other (s) through a metallization cell (4), forming on the band, 5 electrical contacts (9a- 9h) per zone. Each contact has a shape which encompasses a rectangle of length 2 millimetres (mm) and width 1.7 mm. A summed surface area of the contacts is less than 127.01 mm2.