Flexible Circuit Board Press-Fit Connection via Attachment Piece
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Solution Overview
Problem
Flexible circuit boards in motor vehicle control devices face challenges in establishing reliable connections with metal contacts due to their flexibility and thinness, as they cannot absorb spring force from press-fit pins, leading to weaknesses in laser welding and critical positioning issues with soldering methods.
Innovation Solution
A method involving a mechanically coupled attachment piece with a sleeve that receives a press-fit pin, providing necessary stiffness and space for a robust connection, where the attachment piece is soldered or laminated to the flexible circuit board, and optionally using a crimping part with a crimping region to establish electrical contact with the metal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a press-fit pin is used to contact the flexible circuit board, then electrical connection is established, but the flexible circuit board cannot absorb the spring force due to its thinness and flexibility
Solution Approach 1:
A reinforcement element is introduced as an intermediary component between the press-fit pin and the flexible circuit board. This reinforcement element absorbs the spring force of the press-fit pin through its own mechanical properties, preventing damage to the thin flexible circuit board while maintaining reliable electrical connection.
Solution Approach 2:
The solution combines the flexible circuit board with a reinforcement element made of different material properties (higher stiffness and strength). This composite structure allows the system to simultaneously achieve flexibility where needed and mechanical strength where required to withstand the press-fit pin's spring force.
2Ease of manufacture
If laser welding is used to connect the flexible circuit board with metal contacts, then connection is established, but local reduction in strength occurs
Solution Approach 1:
The patent replaces the laser welding process with a mechanical connection system using a press-fit pin and reinforcement element. This substitution eliminates the thermal process that causes local strength reduction while maintaining manufacturing efficiency through automated insertion processes.
3Ease of manufacture
If soldering is used to connect the flexible circuit board with metal contacts, then electrical connection is established, but position during soldering is extremely critical
Solution Approach 1:
The soldering process is replaced with a mechanical press-fit connection system. The reinforcement element provides a stable mounting surface that positions the metal contact precisely, eliminating the critical positioning requirements of soldering while maintaining manufacturing simplicity.
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 ensures a reliable, mechanically stable, and electrically conductive connection between the flexible circuit board and metal contact, avoiding the weaknesses of existing methods by providing the necessary rigidity and space for press-fit pins, and allowing for secure attachment without compromising the flexibility of the circuit board.
Implementation Method 1
The press-fit pin in the region of the press-fit zone has elastic properties (for example, eye-of-the-needle geometries, needle-eye shape). The geometry is compressed by being pressed into the sleeve, where the elastic restoring force presses the press-fit pin against the internal wall of the sleeve.
Implementation Method 2
The attachment piece is soldered or laminated to the flexible circuit board
Implementation Method 3
The attachment piece is soldered or laminated to the flexible circuit board
Data Source
AI summary
The disclosure relates to a method for contacting a contact surface on a flexible circuit board with a metal contact outside the flexible circuit board, with the aid of a press-fit pin. An attachment piece having a sleeve for receiving the press-fit pin is a mechanically and electrically coupled to the flexible circuit board.