Flexible PCB Electronic Module for Compact Board Integration
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Solution Overview
Problem
Existing electronic modules, particularly power electronic circuit carriers, require complex and costly connections between multiple boards, increasing construction complexity and cost.
Innovation Solution
An electronic module design featuring a first carrier element and a flexible second carrier element that encompasses the first, creating a compact structure with integrated electrical contacts, eliminating the need for additional connectors by using flexible printed circuit boards and press-fit contact pins for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple boards are connected using special plug connectors and contacts, then electrical connection between boards is achieved, but construction complexity and cost increase
Solution Approach 1:
The patent merges the functions of multiple separate boards into a single integrated circuit carrier. The power electronic circuit components are directly mounted on one carrier element, eliminating the need for separate boards and plug connectors. This integration maintains reliable electrical connections while significantly reducing construction complexity.
Solution Approach 2:
The patent extracts and eliminates the unnecessary plug connectors and intermediate contact elements from the system. By directly mounting power electronic circuit components on the circuit carrier, the design removes the complex connection infrastructure while preserving the essential electrical connectivity function.
2Reliability
If multiple boards are connected using special plug connectors and contacts, then electrical connection between boards is achieved, but cost increases
Solution Approach 1:
The patent combines multiple functional boards into a single integrated circuit carrier design. This merging eliminates the need for expensive plug connectors and multi- board assembly processes, thereby reducing manufacturing costs while maintaining reliable electrical connections for power electronic circuits.
Solution Approach 2:
The patent adopts a cost-effective approach by using a single disposable circuit carrier instead of expensive reusable plug connectors and contact elements. The integrated carrier provides all necessary electrical connections in one affordable component, reducing overall manufacturing expenses.
3Device complexity
If a compact construction is achieved by integrating carrier elements, then the number of component parts is reduced, but manufacturing complexity may increase
Solution Approach 1:
The patent segments the circuit carrier into functional regions (first and second regions) with different properties. This segmentation allows each region to be optimized for its specific function while maintaining overall integration, making the manufacturing process more manageable despite the compact design.
Solution Approach 2:
The patent applies local quality by creating regions with different characteristics on the same carrier element. The first region has properties suited for certain components while the second region has properties for other components, enabling compact integration without compromising manufacturability through localized optimization.
Data Source
AI summary
An electronic module includes a first supporting element, a second supporting element, and a plurality of components arranged on the first supporting element and the second supporting element. The first supporting element and the second supporting element are electrically conductively connected, and the second supporting element forms an intermediate chamber in which the first supporting element is arranged.