Flexible Circuit Board Disconnection Prevention Mechanism

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Solution Overview

Problem

Circuit boards face disconnection issues when bent, and existing solutions that use adhesive layers to prevent this increase manufacturing costs and are limited to specific folding types.

Innovation Solution

A circuit board design with a disconnection preventing portion that electrically couples areas of the circuit pattern without fixing them, positioned at the boundary between areas on the base material, allowing for both mountain and valley folds without an adhesive layer, using materials with lower elastic modulus to reduce damage and maintain coupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If an adhesive layer is used to maintain valley fold, then the circuit board can be bent into valley fold, but manufacturing costs increase

Engineering Contradiction:

Improvebending capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention extracts and removes the adhesive layer from the circuit board structure, replacing it with a disconnection preventing portion that serves the same protective function without requiring additional adhesive materials or complex lamination processes, thereby reducing manufacturing costs while maintaining bending capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the material parameter of the circuit board by using a bendable base material with specific flexibility characteristics, allowing the board to be bent into both valley folds and mountain folds without requiring adhesive layers to maintain the fold structure

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the circuit board is bent into valley fold with adhesive layer, then disconnection is prevented, but the solution is limited to specific folding types

Engineering Contradiction:

Improvedisconnection preventionVSAvoidfolding type compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The disconnection preventing portion is designed with universal functionality that works for both valley folds and mountain folds. By positioning it at the boundary between first and second areas, it provides disconnection prevention across different folding scenarios without requiring configuration changes or additional components

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of using an adhesive layer to maintain the valley fold structure, the invention inverts the approach by using a disconnection preventing portion that actively protects the circuit pattern from disconnection regardless of the fold type, making the solution applicable to both valley and mountain folds

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If disconnection preventing portion is provided in boundary portion, then it prevents disconnection in mountain fold, but may cause damage in valley fold

Engineering Contradiction:

Improvedisconnection preventionVSAvoiddamage resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention applies local quality by providing the disconnection preventing portion with specific material properties (lower elastic modulus) at the boundary region where it is most needed for disconnection prevention, while the rest of the circuit board maintains its original structural integrity and damage resistance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The disconnection preventing portion uses material with a lower elastic modulus than the circuit pattern, allowing it to deform more easily and absorb stress during valley folds, thereby preventing disconnection without causing damage to the overall structure

Inventive Principle:

Principle #35Parameter changes

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

Effectively prevents disconnection of the electric circuit pattern during bending while reducing manufacturing costs by minimizing the area where the disconnection preventing portion is applied, maintaining electrical coupling in both fold types without the need for an adhesive layer.

Implementation Method 1

a position where the disconnection preventing portion with at least a portion positioned on one of the first area and the second area in the electric circuit pattern portion contacts the other one of the first area and the second area in the electric circuit pattern portion in a state where the circuit board is bent at the folding portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20240349420A1Circuit board

Publication Date: 2024.10.17 JOHNAN CORP

AI summary

A circuit board includes a base material portion having a sheet-like shape, an electric circuit pattern portion being formed on at least one of surfaces of the base material portion and being conductive, a folding portion where a linear fold is to be formed to divide, when the circuit board is bent, each of the base material portion and the electric circuit pattern portion into a first area and a second area, and a disconnection preventing portion that prevents disconnection between the first area and the second area in the electric circuit pattern portion in a state where the circuit board is bent at the folding portion.