FPCB Grounding via Folded Substrate Stiffening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light modules for motor vehicles using flexible printed circuit boards (FPCBs) face challenges in ground recovery, requiring additional components and occupying more volume, which increases production costs and reduces design flexibility in restricted spaces.
Innovation Solution
A light module design featuring a metallic ground device with a flexible substrate and a support plate, where the flexible substrate is stiffened by a foldable second portion that establishes a ground connection without additional dedicated components, allowing for efficient ground recovery and reduced part usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically conductive rivets are used to ground the FPCB, then grounding is achieved, but the usable area of the printed circuit board is reduced and device complexity increases
Solution Approach 1:
The substrate integrates both structural support and electrical grounding functions into a single component. The substrate includes a first portion that supports electronic components and a second portion that provides grounding through an electrically conductive trace, eliminating the need for separate grounding rivets or components.
Solution Approach 2:
The substrate serves multiple functions: it provides mechanical support for electronic components, acts as an electrical insulator where needed, and provides electrical grounding through its conductive trace. This multi-functionality reduces the overall component count and simplifies the device structure.
2Reliability
If additional grounding components are used, then grounding is ensured, but volume occupation increases
Solution Approach 1:
The grounding function is merged into the substrate itself rather than being implemented as a separate component. The second portion of the substrate contains an electrically conductive trace that directly provides grounding, eliminating the volume occupied by additional grounding components.
3Ease of operation
If the substrate is kept fully flexible, then ease of placement is improved, but structural support for components is reduced
Solution Approach 1:
The substrate is divided into two distinct portions: a first portion that is flexible and supports electronic components, and a second portion that provides structural reinforcement and grounding. This segmentation allows each portion to be optimized for its specific function while working together as a unified structure.
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 solution enables ground connection for electronic circuits on FPCBs using the substrate's flexibility, reducing the need for extra components and minimizing volume occupation, thereby lowering production costs and enhancing design flexibility in motor vehicle lighting systems.
Implementation Method 1
a single fold of the substrate relative to the first portion of substrate, the fold being such that the second portion of substrate is in contact with said support plate and such that the electrically conductive trace achieves grounding
Data Source
Figure 1~3
Figure 4a~7
AI summary
The invention provides a lighting module comprising a flexible substrate integrated circuit of the FPCB type. The grounding of the electronic circuit housed on the printed circuit board is achieved without the need for additional mounting hardware. Compared to known techniques in the art, the invention allows for the creation of a lighting module with fewer component parts and a smaller footprint.