Flexible Printed Circuit Electrical Connector Design
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Solution Overview
Problem
The design and manufacturing of high-density electrical connectors are challenging due to the need for precise sizing, spacing, and location of individually machined or stamped electrical contacts, which requires expensive equipment and materials.
Innovation Solution
An electrical connector system featuring a flexible printed circuit with solder pads, contact pads, and links on a flexible substrate, surrounded by a base and partially enclosed by a receptacle, allowing for high-density electrical connections with reduced manufacturing complexity and cost through the use of a flexible substrate and selective connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If individually machined or stamped electrical contacts are used to achieve high-density electrical connections, then connection density is improved, but manufacturing complexity and cost increase due to precise sizing, spacing, and location requirements
Solution Approach 1:
The electrical connector is divided into modular components: a flexible printed circuit board containing multiple electrical contacts, a base structure, and a receptacle. This segmentation allows each component to be manufactured separately with standard processes, then assembled together, reducing overall manufacturing complexity while maintaining high connection density
Solution Approach 2:
The patent transitions from traditional planar connector layouts to a three-dimensional configuration where the flexible printed circuit board can be folded or bent to achieve compact spatial arrangement. This dimensional change enables high-density connections in a smaller footprint without requiring precision machining of each contact
2Quantity of substance
If individually machined or stamped electrical contacts are used to achieve high-density electrical connections, then connection density is improved, but manufacturing cost increases due to expensive equipment and materials
Solution Approach 1:
Multiple electrical contacts are merged onto a single flexible printed circuit board, which is manufactured using standard PCB fabrication processes. This combining approach eliminates the need for expensive individual machining or stamping operations for each contact, significantly reducing manufacturing cost while maintaining high connection density
Solution Approach 2:
The flexible printed circuit board serves as a template or copy that can be repeatedly manufactured using standardized PCB design and fabrication processes. This allows for consistent reproduction of high-density contact patterns at low cost through batch production rather than individual customization
Data Source
AI summary
Disclosed herein is an electrical connector. The electrical connector comprises a flexible printed circuit comprising electrical elements on a flexible substrate. The electrical elements each comprises a solder pad and contact pad connected by a link. The electrical connector also comprises a base to at least partially surround the flexible printed circuit. The base comprises a connection interface to facilitate electrical connection with the flexible printed circuit through the base. The electrical connector further comprises a receptacle to couple to the base to partially enclose the flexible printed circuit. The receptacle exposes a portion of the flexible printed circuit to facilitate selective electrical connection with the flexible printed circuit through the receptacle.