3D Flexible PCB Layout for Space-Constrained Circuit Breakers
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Solution Overview
Problem
Conventional circuit breaker circuit boards face design challenges due to space restrictions, requiring innovative solutions to accommodate complex electronic components while ensuring sufficient creepage distance and electrical gaps.
Innovation Solution
A flexible circuit board design comprising multiple hard circuit boards connected by a flexible connecting member that forms a three-dimensional spatial layout, allowing for both structural and electrical connections between boards, thereby overcoming spatial limitations and ensuring adequate gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional rigid circuit board is used in circuit breaker design, then electrical connections and component mounting are straightforward, but the board cannot be configured in three-dimensional spatial layouts and insufficient creepage distance and electrical gaps occur under space restrictions
Solution Approach 1:
The circuit board is divided into multiple independent rigid circuit boards (first circuit board, second circuit board, etc.) that can be separately positioned and connected through flexible connecting members, enabling three-dimensional spatial distribution while maintaining adequate electrical clearance and creepage distance between boards
Solution Approach 2:
The circuit board configuration transitions from a traditional two-dimensional planar layout to a three-dimensional spatial layout by vertically stacking multiple circuit boards and connecting them through flexible connecting members, thereby utilizing vertical space and achieving both compact volume and sufficient electrical gaps
2Volume of moving object
If the circuit board is divided into multiple separate boards to achieve three-dimensional layout, then space utilization improves and adequate gaps are ensured, but the structural complexity and connection difficulty increase
Solution Approach 1:
Flexible connecting members (such as flexible printed circuit boards or cable assemblies) are used to connect the multiple rigid circuit boards, providing both mechanical support and electrical connection in a single integrated component that can accommodate three-dimensional spatial arrangements
Solution Approach 2:
The flexible connecting members serve dual functions: they provide mechanical support/structural connection between circuit boards and simultaneously establish electrical connections between corresponding circuit terminals, simplifying the overall system architecture
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Disclosed in the present invention are a flexible circuit board 1 and a circuit breaker thereof. The flexible circuit board comprises multiple circuit boards (11, 12, 13) and at least one flexible connecting member (21, 22); the circuit boards are hard circuit boards. The flexible connecting member is connected between the independent multiple circuit boards, such that the multiple circuit boards form a circuit board connected by the flexible connecting member, the flexible connecting member being bent such that the multiple circuit boards form a three-dimensional spatial layout. The present invention solves the technical problem that an entire conventional circuit board cannot be designed when it is subject to space restrictions.