Flexible Printed Circuit Wire-to-Meter Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motorcycle dashboard wire connection methods are prone to assembly difficulties due to unpredictable wire buckling, are susceptible to vibration-induced failure, and can allow moisture ingress, leading to reliability issues and increased assembly time and cost.
Innovation Solution
A conductor assembly with a rigid, planar component and a flexible, ribbon-like portion with printed conductive traces that allows controlled bending and secure, water-resistant connection of wire bundles to the main circuit board, eliminating the need for individual wire soldering and reducing mass to mitigate vibration effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual wires are soldered to the PCB and extended to the connector, then electrical connection is achieved, but the wires buckle unpredictably during assembly and are susceptible to vibration-induced failure
Solution Approach 1:
The patent combines multiple separate wire connections into a single flexible printed circuit board (FPC) assembly. The FPC integrates multiple conductive traces that replace individual wires, eliminating the need for separate soldering and routing of each wire. This merging approach reduces assembly complexity while maintaining reliable electrical connections between the PCB and connector.
Solution Approach 2:
The patent replaces the mechanical wire routing and soldering system with a flexible printed circuit board that uses controlled flexibility to accommodate bending. The FPC's inherent flexibility replaces the need for manual wire bending and securing mechanisms, while its rigid trace structure provides vibration resistance compared to loose individual wires.
2Ease of operation
If wire length is increased to facilitate handling during assembly, then ease of assembly is improved, but wire mass increases leading to greater vibration-induced damage
Solution Approach 1:
The patent uses a flexible printed circuit board made of thin flexible substrate material that can be easily handled and positioned during assembly. The FPC's flexibility allows it to conform to the desired path between the PCB and connector without requiring excessive length, reducing mass while maintaining assembly ease. The thin film structure provides sufficient flexibility for positioning but minimal mass to reduce vibration effects.
3Strength
If stiffer insulating jackets are used over wires connected to lead-free solder, then connection strength is improved, but wire mass increases returning the vibration problem
Solution Approach 1:
The patent replaces individual wire-solder-connector assemblies with a flexible printed circuit board that has traces directly patterned on the substrate. This eliminates the need for separate insulating jackets over individual wires, as the FPC substrate itself provides insulation. The solder joints are made to the FPC traces, which are inherently rigid and vibration-resistant, without requiring additional stiffening jackets that would increase mass.
4Reliability
If epoxy is used to fill the well for strain relief and water prevention, then protection against moisture and wire stress is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent positions the flexible printed circuit board to naturally follow the contour of the well structure, with the FPC extending through the back wall and connecting to the connector in a predetermined path. This preliminary positioning eliminates the need for additional epoxy filling for strain relief, as the FPC's flexibility and routing provide inherent stress accommodation. The design integrates protection functions into the FPC structure itself, simplifying manufacturing.
Data Source
AI summary
A robust and waterproof wires-to-meter connection that provides an apparatus for conducting signals from several signal-carrying, bundled wires to a circuit member that is mounted within the interior of a sealed case, and in particular an assembly for conducting the signals while providing a robust, compact and water-resistant connection between the internal main circuit and the entry wires.