Molded Article With Through-Hole Routing For Flexible Wiring Protection
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Solution Overview
Problem
Existing molded articles with integrated circuit films and molded bodies face issues with flexible printed boards being damaged during handling due to interference with the housing, leading to broken wiring lines, especially when the board is routed through clearances in electrical products.
Innovation Solution
A molded article design featuring a circuit film with a thermoplastic insulating film and an electrical circuit, where a flexible wiring portion is formed by cutting the wiring line's periphery while maintaining connection with the insulating film, and a through-hole in the molded body allows the flexible wiring portion to pass through, with a connection terminal positioned within or beyond the other main surface, reducing the risk of damage and improving connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flexible printed board is drawn out from the end portion of the resin portion, then the electrical device can be connected to the circuit film, but the flexible printed board interferes with the housing and may be broken during handling
Solution Approach 1:
The flexible printed board is routed through a through-hole in the molded body, transitioning from a surface-level routing (2D) to a three-dimensional path through the component module (3D). This dimensional change allows the board to pass through the interior space of the housing without interfering with external components, eliminating the risk of breakage during handling while maintaining electrical connectivity.
2Adaptability or versatility
If the flexible printed board is routed through clearances in the housing, then connectivity is achieved, but the board interferes with the housing and wiring lines may break
Solution Approach 1:
The through-hole in the molded body serves as an intermediary structure that facilitates the passage of the flexible printed board from the exterior to the interior space of the housing. This intermediary pathway allows the board to connect electrical devices without directly interfacing with or interfering with the housing structure, thereby preventing wiring line breakage while maintaining adaptability for electrical connectivity.
3Ease of manufacture
If the connection terminal is positioned at the end portion of the resin portion, then manufacturing is simplified, but the flexible printed board must be routed externally causing interference
Solution Approach 1:
The through-hole is pre-formed in the molded body during the injection molding process, before the flexible printed board is installed. This preliminary action integrates the routing pathway into the manufacturing process itself, allowing the board to be subsequently routed through the hole without requiring complex post-manufacturing modifications or external routing configurations, thereby simplifying both manufacturing and device 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 configuration facilitates the layout of wiring lines from the circuit film to the connection terminal, preventing damage and ensuring reliable electrical connections within the electrical product, while also enhancing design aesthetics and protection against foreign matter entry.
Implementation Method 1
a circuit film (20) and a molded body (30) which is integrally molded with the circuit film (20)
Implementation Method 2
a flexible wiring portion (25) formed by cutting a periphery of a wiring line (27) connected to the electrical circuit (22) while maintaining connection with the insulating film (21)
Data Source
AI summary
A molded article or an electrical product facilitates layout of a wiring line from an electrical circuit of a circuit film integrally molded with a molded body to a connection terminal. The molded article includes a circuit film and a molded body. The circuit film includes an insulating film and an electrical circuit. The molded body is integrally molded with the circuit film. The circuit film includes a flexible wiring portion. The molded body has a through-hole that penetrates from a first main surface to a second main surface. In the flexible wiring portion, a connection terminal is arranged at a position of passing through the through-hole and beyond the second main surface.