Flexible Printed Circuit Board Bending for Curved Vehicle Door Handles
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Solution Overview
Problem
Conventional motor vehicle door handles with integrated electronic assemblies face challenges in adapting to curved designs due to the need for multiple printed circuit boards, which are prone to damage when bent to fit the shape.
Innovation Solution
A single printed circuit board with strategically weakened areas, achieved through material removal, allowing for bending without damaging conductor tracks or electronic components, enabling adaptation to curved door handle designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional printed circuit board is bent to fit the curved design of the door handle, then the door handle can be adapted to the curved shape, but the conductor tracks or electronic components on the circuit board are damaged
Solution Approach 1:
The circuit board is divided into multiple sections with different flexibility characteristics. Rigid sections maintain structural integrity and electrical connections, while flexible sections with reduced material thickness allow bending without damage. This segmentation enables the circuit board to conform to the curved door handle shape while protecting conductor tracks and components.
Solution Approach 2:
Different regions of the circuit board are given different material properties. The flexible sections have locally reduced thickness (material removal of 20-80%) to enable bending, while other regions maintain full thickness for rigidity and component mounting. This local variation in quality allows selective flexibility where needed while maintaining overall structural integrity.
2Adaptability or versatility
If multiple individual circuit boards are used to provide complex electronic functions, then the electronic assembly can perform multiple functions, but the device complexity and number of connection areas increase
Solution Approach 1:
Multiple circuit boards with different electronic functions are merged into a single integrated circuit board structure. The flexible sections allow this single board to conform to the curved door handle shape while maintaining all necessary electronic functions that would otherwise require separate boards. This reduces the number of connection areas and simplifies the overall assembly.
Solution Approach 2:
The integrated circuit board is designed to perform multiple electronic functions within a single structure. By combining various electronic components and conductor tracks on one flexible board, the design achieves multi-functionality without requiring multiple separate circuit boards, thereby reducing complexity while maintaining versatility.
3Adaptability or versatility
If material is removed from the printed circuit board to create a bending area, then the circuit board can be bent without damage, but the manufacturing process becomes more complex
Solution Approach 1:
The material removal to create flexible sections is performed during the initial circuit board manufacturing process, before the board is assembled into the door handle. This preliminary action integrates the flexibility feature into the base production workflow, avoiding the need for separate post-processing steps and minimizing additional manufacturing complexity.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an electronic assembly, particularly for installation in a motor vehicle door handle, comprising at least one printed circuit board (1) having conductive traces and populated with electronic components, wherein the printed circuit board (1) has at least one section with a material weakening to form a bending area (3, 3'), wherein the material weakening of the printed circuit board is formed by material removal, in particular by milling (2, 2') of more than half, in particular more than two-thirds, of the thickness (D) of the printed circuit board (1). The invention further relates to a method for manufacturing a motor vehicle door handle with such an electronic assembly.