Flexible Printed Circuit Board Manufacturing via Partial FPC Segmentation
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Solution Overview
Problem
The existing manufacturing methods for flexible printed circuit boards face challenges in achieving efficient sheet layout and high yield due to the large area size and fine wiring pitch, leading to increased manufacturing costs and reduced yield rates, especially when forming fine wirings with a high probability of defects from foreign substances.
Innovation Solution
The method involves manufacturing partial flexible printed circuit boards with divided component mounting sections and flexible cable sections, allowing for positional alignment and combination to form a component mounting section, which reduces the area size and number of extending directions, enhancing sheet layout efficiency and reducing the impact of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the component mounting section is manufactured as a single large unit with fine wirings, then the wiring density and functionality are improved, but the manufacturing yield decreases due to high probability of defects from foreign substances
Solution Approach 1:
The component mounting section is divided into multiple divided sections that are manufactured separately on the flexible substrate. Each divided section contains a portion of the fine wirings and connection terminals. By segmenting the manufacturing process into multiple smaller units, the impact of foreign substance defects is localized to individual divided sections rather than affecting the entire component mounting section, thereby improving overall manufacturing yield while maintaining fine wiring precision in each segment.
2Adaptability or versatility
If the flexible printed circuit board has a large area to accommodate multiple cable sections extending in different directions, then the functionality and adaptability are improved, but the sheet layout efficiency decreases leading to increased manufacturing costs
Solution Approach 1:
The flexible printed circuit board is divided into multiple flexible substrate units, each containing a component mounting section with divided sections and associated cable sections. This segmentation allows for more efficient packing and arrangement of multiple boards on a manufacturing sheet, improving sheet layout efficiency and reducing manufacturing costs while maintaining the ability to configure cable sections in different directions through the modular unit design.
Data Source
AI summary
[Problem] To allow an efficient sheet layout of a flexible printed circuit board having a plurality of cable sections extending in different directions and to improve a yield.[Solution] A method of manufacturing a flexible printed circuit board that includes a component mounting section (1) having lands (1a), a plurality of flexible cable sections (2) having wirings and extending in different directions from the component mounting section (1), and a connection section (3) having terminals (3a) connected with the land (1a) through the wiring, the method including manufacturing partial FPCs in a sheet in a unit of a partial FPC that includes a partial component mounting section (1A) that is a part of the component mounting section, a cable section (2) extending from the partial component mounting section (1A), and a connection section (3) disposed in the cable section (2), cutting out the partial FPC (4A) from the sheet, performing an alignment using alignment targets (29, 30) of the partial FPC (4A) and a support plate (5) so that the partial component mounting sections (1A) of respective partial FPCs (4A) configure the component mounting section (1), and fixing the partial FPCs (4A) onto the support plate.