Flexible Substrate with Bent Portions for Compact Connector Design

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Solution Overview

Problem

Existing electronic devices face challenges in maintaining a compact design due to the need for a flexible substrate to connect two connectors, which can become damaged when bent excessively, and may not adequately cope with positional displacements of the connectors.

Innovation Solution

The electronic device incorporates a flexible substrate with strategically positioned bent portions that allow it to be bent in opposite directions, reducing the distance between connectors and preventing damage from self-contact, while also accommodating potential positional offsets between the connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If a flexible substrate is bent to connect two connectors, then the distance between connectors can be reduced, but the flexible substrate may become damaged from excessive bending

Engineering Contradiction:

Improvedistance between connectorsVSAvoidflexible substrate damage

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The flexible substrate is divided into multiple sections by introducing multiple bent portions (first bent portion, second bent portion, third bent portion) instead of a single continuous bend. This segmentation distributes the bending stress across multiple locations, preventing excessive stress concentration at any single point and reducing the risk of substrate damage while achieving the required compact distance between connectors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible substrate incorporates multiple curved bent portions with specific radii of curvature. These controlled curvatures allow the substrate to flex smoothly between connectors without sharp angles that would concentrate stress. The curved geometry enables the substrate to accommodate the distance reduction while maintaining structural integrity and preventing damage from excessive bending.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If the flexible substrate is made longer to accommodate positional displacements, then connector misalignment can be tolerated, but the device size increases

Engineering Contradiction:

Improvepositional displacement toleranceVSAvoiddevice size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The flexible substrate with multiple bent portions creates a dynamic structure that can adapt to positional variations between connectors. The bent portions act as flexible joints that can adjust their angles and positions within certain ranges, allowing the substrate to accommodate connector misalignment dynamically without requiring excessive length. This dynamic adaptability enables the substrate to maintain electrical connection despite positional displacements while keeping the overall device size compact.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the geometric parameters of the flexible substrate by introducing multiple bent portions with specific curvature radii and angles. These parameter changes enable the substrate to achieve both compact size and adaptability. The multiple bends create a configuration that can tolerate positional variations through geometric adjustment rather than requiring increased substrate length, thus maintaining small device dimensions while providing displacement tolerance.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If multiple bent portions are added to the flexible substrate, then positional displacement can be accommodated and damage suppressed, but the substrate structure becomes more complex

Engineering Contradiction:

Improvesubstrate damage suppressionVSAvoidsubstrate structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flexible substrate is segmented into multiple sections separated by bent portions, which simplifies the overall structure compared to a single long flexible connection. Each segment between bent portions can be optimized independently, and the segmentation allows the substrate to achieve reliability through distributed stress management while maintaining a relatively simple and modular structure that is easier to manufacture and assemble.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250147555A1Electronic device and production method for electronic device

Publication Date: 2025.05.08 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An electronic device according to the present disclosure includes: a first substrate on which a first connector is mounted; a second substrate that is disposed with a gap with respect to the first substrate in a first direction, and on which a second connector is mounted; and a flexible substrate having one end and another end, with the one end being connected to the first connector, and the other end being connected to the second connector. The first connector and the second connector face each other in the first direction. The flexible substrate further includes a first bent portion, and a second bent portion that is positioned on a side nearer to the other end than the first bent portion. The flexible substrate extending from the first connector is bent at the first bent portion toward one side in a second direction that is orthogonal to the first direction, and extends further toward the one side in the second direction with respect to the first substrate. The flexible substrate extending from the second connector is bent at the second bent portion toward the other side in the second direction, and extends further toward the other side in the second direction with respect to the second substrate.