Flexible-Rigid PCB Composite with Elastic Connecting Elements
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Solution Overview
Problem
The production of flexible-rigid circuit board composites is hindered by high production costs and decreased cycle time due to the difficulty in automating the handling and positioning of isolated flexible connecting bridges, particularly in small PCB structures used in medical implants.
Innovation Solution
A flexible circuit board design featuring elastically connected planar segments with embedded flexible connecting elements that can be precisely aligned and connected to rigid circuit boards, allowing for automated production and integration of components without interfering with existing components on the rigid board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If discrete hot bar soldering or laser soldering is used to fasten flexible connecting bridges to rigid PCBs, then connection precision can be achieved, but production costs increase and cycle time decreases due to difficulty in automation
Solution Approach 1:
The patent merges multiple flexible connecting bridges with rigid PCBs onto a single carrier, enabling parallel processing. Instead of handling isolated flexible bridges separately, the entire assembly is processed together through alignment and soldering operations, significantly improving automation capability and productivity while maintaining connection precision.
Solution Approach 2:
The patent segments the production process into distinct phases: first assembling multiple flexible bridges on a carrier, then performing collective alignment and soldering. This segmentation allows the system to handle groups of components simultaneously rather than individually, resolving the contradiction between precision and productivity.
2Manufacturing precision
If isolated flexible connecting bridges are handled and positioned manually or semi-automatically, then connection accuracy can be maintained, but production costs increase and automation is difficult
Solution Approach 1:
Multiple flexible connecting bridges are merged onto a single carrier structure, transforming them from isolated components that are difficult to automate into a unified assembly that can be handled and positioned as one unit. This enables full automation while maintaining connection accuracy through the carrier's structural integrity.
Solution Approach 2:
The carrier acts as an intermediary structure that holds multiple flexible connecting bridges in predetermined positions. This intermediary enables automated systems to handle the entire assembly without needing to manipulate each individual flexible bridge, thereby improving automation capability while preserving connection accuracy.
3Manufacturing precision
If multiple flexible connecting bridges are processed in discrete steps, then individual connection quality can be ensured, but production throughput decreases
Solution Approach 1:
The patent enables continuous processing by assembling multiple flexible connecting bridges on a carrier in one setup, then performing alignment and soldering operations on all bridges simultaneously. This eliminates the need for repeated discrete steps for each bridge, maintaining individual connection quality while significantly improving production throughput.
Solution Approach 2:
Multiple flexible connecting bridges are preliminarily assembled and positioned on the carrier before the actual soldering process. This preliminary arrangement allows subsequent processing steps to be performed on all bridges in parallel, ensuring individual connection quality while maximizing production throughput through batch processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high-precision, cost-effective production of flexible-rigid circuit board composites with reduced production costs and increased throughput, particularly suitable for small medical implant applications.
Implementation Method 1
the at least one planar segment comprise at least one flexible connecting element, which is elastically connected to a face of the at least one first planar segment
Data Source
AI summary
A flexible circuit board for producing a flexible-rigid circuit board composite made of at least one flexible circuit board and at least one rigid circuit board, the at least one flexible circuit board having at least one first planar segment, which interacts as intended in the installed state with at least one second planar segment of the at least one rigid circuit board, wherein the at least one first planar segment comprises at least one flexible connecting element, which is elastically connected to a face of the at least one first planar segment. Furthermore, a flexible-rigid circuit board composite is provided having at least one flexible circuit board, a flexible-rigid circuit board arrangement, and a method and a device for producing a flexible-rigid circuit board composite.