Flexible Printed Circuit Plug Connection for Tool-Free Assembly

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Solution Overview

Problem

Existing light-emitting systems face challenges in easily and efficiently connecting flexible printed circuits with light-emitting apparatuses to power sources or each other, often requiring complex processes like soldering and additional tools.

Innovation Solution

A light-emitting system featuring flexible printed circuits with integral plug connections that allow for force-free insertion and mechanical fixation, eliminating the need for soldering by using plug connections like FFC or ZIF, and optionally integrating solder projections for easy electrical contact with supply lines or other circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to connect flexible printed circuits to power sources or other circuits, then reliable electrical connection is achieved, but manufacturing complexity and time increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the thermal-mechanical soldering process with a purely mechanical plug connection system. The plug connection comprises contact elements that establish electrical contact through mechanical insertion, eliminating the need for soldering irons, flux, and heating processes. This substitution maintains electrical connection reliability while dramatically simplifying the manufacturing process and reducing production time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a plug connection as an intermediary component between the flexible printed circuit and the power source or other circuits. This plug connection includes contact elements that mate with contact areas on the flexible printed circuit, providing a standardized interface that simplifies both manufacturing and assembly processes while ensuring reliable electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If soldering processes are used for connecting supply lines to flexible printed circuits, then electrical contact is established, but production time and manufacturing difficulty increase

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The plug connection and contact areas are pre-formed during the manufacturing of the flexible printed circuit and power source components, respectively. This preliminary preparation allows for rapid assembly through simple insertion without requiring on-site soldering operations, thereby significantly increasing production speed while maintaining reliable electrical contact.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the time-consuming soldering process with a quick mechanical insertion operation. The plug connection is designed to be inserted into a receptacle and fixed in place through simple mechanical means such as clips or latches, eliminating the need for heating, cooling, and cleaning operations associated with soldering, thus dramatically improving production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If additional tools and equipment are used for soldering connections, then reliable electrical joining is achieved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveelectrical joining reliabilityVSAvoidmanufacturing equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the electrical connection function from the complex soldering process and encapsulates it in a simple plug connection mechanism. By separating the electrical contact function from the thermal-mechanical soldering process, the design eliminates the need for specialized soldering equipment, flux, and associated safety equipment, thereby reducing device complexity and manufacturing cost while maintaining reliable electrical joining.

Inventive Principle:

Principle #2Taking out (Extraction)

4Device complexity

If flexible printed circuits are connected without plug connections, then simpler structure is achieved, but connection and disconnection become difficult

Engineering Contradiction:

Improveconnection structure simplicityVSAvoidconnection ease

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The plug connection is designed as a universal interface that serves multiple functions: establishing electrical contact, providing mechanical support, enabling easy insertion and removal, and ensuring proper alignment. This multi-functional design achieves connection ease without significantly increasing structural complexity, as the same plug connection mechanism handles all these requirements simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7771204B2Light-emitting system with a plug connection

Publication Date: 2010.08.10 OPTOTRONIC GMBH

AI summary

A light-emitting system is provided, in which a flexible printed circuit (2) is connected to a plug connection (4) which connects the flexible printed circuit (2) either to a power source or to a second flexible printed circuit (20). The connection of the flexible printed circuit to a second printed circuit or to a power source can be made easily, and can be produced in large quantities.