Flexible Rework Patch for Cracked Circuit Traces
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Solution Overview
Problem
Demounting surface-mounted electronic components from flexible or stretchable electronic circuits results in cracked board traces, leading to open circuits and rendering the circuit non-functional, even when a new component is mounted.
Innovation Solution
A rework patch with a flexible patch body and spaced-apart patch traces is used to cover defect portions of the board traces, and conductive lumps are dispensed to establish electrical connections, allowing reuse of the substrate and easy mounting of replacement components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If surface-mounted electronic components are demounted from the substrate, then the electronic component can be replaced, but the board traces will crack and lead to open circuit
Solution Approach 1:
The invention introduces a separate patch body that segments the repair function from the original board traces. The patch body is applied over the cracked traces, creating a distinct repair layer that restores electrical connectivity without requiring removal of the cracked traces. This segmentation allows component replacement while preserving the underlying damaged traces through the patch overlay.
Solution Approach 2:
The patch body acts as an intermediary element between the cracked board traces and the new electronic component. It provides a new conductive pathway that mediates the electrical connection, allowing current to flow around the cracked traces through the patch traces, thereby restoring circuit functionality without direct contact with the damaged traces.
2Loss of substance
If the substrate is reused after component removal, then material costs are reduced, but the board traces are cracked and the circuit becomes non-functional
Solution Approach 1:
The invention enables recovery of the substrate by applying a patch that restores functionality to cracked traces. Instead of discarding the substrate after component removal, the patch body is applied to recover the electrical pathways, allowing the substrate to be reused for subsequent component mounting while maintaining circuit functionality.
Solution Approach 2:
The invention extracts the repair function into a separate patch component that can be applied independently. The patch body is taken out as a distinct element that carries the conductive traces, separating the repair function from the original board structure and allowing the substrate to be recovered and reused without permanent damage.
3Reliability
If a patch body is applied to cover defect portions, then the board traces are protected from further damage, but the patch traces must be precisely aligned with the board trace pattern
Solution Approach 1:
The patch traces are designed to copy or replicate the pattern of the underlying board traces. By creating a matching trace pattern on the patch body, the invention ensures proper electrical alignment and connection without requiring complex precision alignment mechanisms. The copied pattern naturally aligns with the defects it is meant to cover and bypass.
Solution Approach 2:
The patch body is prepared in advance with pre-defined trace patterns that correspond to the board trace layout. This preliminary preparation of the patch trace pattern allows for easier alignment during application, as the matching patterns guide the placement process and ensure proper electrical connections without requiring high-precision real-time alignment.
Data Source
AI summary
A rework patch for an electronic circuit includes a flexible patch body and at least two patch traces. The electronic circuit includes a substrate, at least two board traces formed on the substrate, and at least one defect portion within at least one of the board traces. The patch body is attached to the substrate to partially cover each of the board traces and to cover the defect portion. The patch traces are formed on the patch body. A pattern of the patch traces corresponds to a pattern of a portion of the board traces covered by the patch body.