Injection Molded Circuit Carrier with Integrated PCB
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronic units with circuit boards require complex and bulky designs to accommodate multiple components, which increases size and production costs, particularly in compact devices like hearing aids.
Innovation Solution
Integrating a circuit board into an injection-molded circuit carrier with conductive tracks, where the circuit board's surface lies within the plastic part and is connected via soldering or conductive adhesive, allowing for a compact and robust electronic unit with high integration levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a circuit board is integrated into an injection-molded circuit carrier with conductive tracks, then the size and complexity of the electronic unit is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent merges the circuit board with the injection-molded circuit carrier by introducing the circuit board into a receptacle formed in the circuit carrier during the injection molding process. The conductive tracks are integrated directly into the circuit carrier, eliminating the need for separate connection elements. This merging of previously separate components (circuit board and circuit carrier) into a single integrated structure reduces the overall size and complexity while the molding process ensures precise positioning and alignment.
2Volume of moving object
If multiple electronic components are packed into a small volume for hearing aids, then the cosmetic appearance is improved, but the device complexity increases
Solution Approach 1:
The patent applies nesting by placing the circuit board inside a receptacle that is formed within the injection-molded circuit carrier. This nested arrangement allows the circuit board to be housed within the three-dimensional structure of the circuit carrier, maximizing space utilization. Additionally, electronic components can be mounted on both the circuit board and the circuit carrier surface, further increasing integration density within the limited volume required for hearing aid applications.
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 simplifies the complexity and size of the electronic unit, enabling a highly integrated and compact design while reducing production costs, suitable for applications like hearing aids with enhanced functionality.
Implementation Method 1
the conductive track of the circuit board and the conductive track of the injection-molded circuit carrier are connected by soldering
Implementation Method 2
the conductive track of the circuit board and the conductive track of the injection-molded circuit carrier are connected with the aid of an electrically conductive adhesive
Data Source
AI summary
An electronic unit has a circuit board that is integrated into an injection molded circuit carrier. A hearing aid is provided with such an electronic unit. In order to reduce the complexity and size of an electronic unit with an injection molded circuit carrier and a circuit board, the circuit board is integrated into the injection molded circuit carrier by introducing the circuit board into the plastic mold such that the surface of a first side of the circuit board lies within the plastic mold and the surface of a second side of the circuit board is substantially flush with the surface of the plastic mold. At least one conductive track of the circuit board is electrically conductively connected to at least one conductive track of the injection molded circuit carrier.