Foldable PCB Capacitor Bank Layout for Tight, Vibration-Prone Spaces
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Solution Overview
Problem
Traditional capacitors are bulky and prone to fatigue damage from vibrations, making them inefficient for use in space-constrained military avionics equipment and requiring large volumes, which complicates packaging and installation in limited spaces.
Innovation Solution
A capacitor bank design featuring printed circuit boards with capacitors mounted on opposing surfaces, allowing for series or parallel connections, and incorporating flexible PCB portions to fold into compact configurations, reducing volume and enhancing vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cylindrical capacitors are used, then adequate voltage ratings and capacitance values are achieved, but the volume occupied is considerable and packaging efficiency is reduced
Solution Approach 1:
The patent transitions from traditional cylindrical capacitors occupying three-dimensional space to ultra-dense cube capacitors mounted on a two-dimensional circuit card assembly plane. This dimensional change allows capacitors to be arranged in arrays on the PCB surface, significantly improving packaging density and reducing the overall volume required for the capacitor bank while maintaining adequate voltage ratings and capacitance values through proper selection and arrangement of individual capacitor elements.
2Quantity of substance
If traditional cylindrical capacitors are used, then good capacitance values are achieved, but installation in units with limited available space is prevented
Solution Approach 1:
The patent divides the capacitor bank into multiple individual ultra-dense cube capacitors mounted on a circuit card assembly. This segmentation allows the capacitance to be distributed across many small components rather than requiring a few large cylindrical capacitors. The modular array configuration enables flexible arrangement to fit limited spaces within military avionics equipment while achieving the required total capacitance value through parallel or series combinations of individual capacitors.
3Reliability
If traditional capacitor construction is used, then adequate performance is provided, but fatigue damage from vibrations occurs
Solution Approach 1:
The patent changes the physical construction parameters of the capacitors from traditional cylindrical forms with susceptibility to vibration fatigue to ultra-dense cube configurations mounted on rigid circuit card assemblies. The cube geometry and PCB mounting provide superior mechanical strength and vibration resistance compared to traditional cylindrical capacitors. This parameter change in form factor and mounting method significantly reduces fatigue damage from vibrations while maintaining electrical performance stability in military avionics environments.
Data Source
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AI summary
A capacitor bank includes a printed circuit board (100) adapted for a first capacitor (102) disposed on a first surface of the printed circuit board and a second capacitor (104) disposed on a second, opposing surface of the printed circuit board. The first and second capacitor are connected to the printed circuit board at surface mounts pads on opposing sides of the printed circuit board that may be in electronic communication with each other. The capacitors may be connected in series or parallel. Multiple printed circuit boards with capacitors on opposing surfaces may include flexible printed circuit board portions to allow the capacitor bank to be folded into an available space.