3D PCB Angled Channel Fabrication for Non-Orthogonal Connections
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Solution Overview
Problem
Manufacturing three-dimensional RF system components with non-orthogonal angles, such as 45 degrees, is challenging due to the complexity and cost of standard printed circuit board (PCB) manufacturing techniques, which often result in high costs and reduced reliability, especially when cutting along the edge of PCBs, where mechanical strength and multi-layer anisotropy are concerns.
Innovation Solution
A method involving the formation of angled channels and support members on PCBs using conical milling to create a ramp portion, allowing for connections at arbitrary angles without requiring special milling heads or machines, using general PCB manufacturing processes and enabling connections between PCBs or other components at specific angles without orthogonal constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard PCB manufacturing techniques are used to create non-orthogonal angles (e.g., 45 degrees), then the desired angular connection is achieved, but the manufacturing cost increases and reliability decreases
Solution Approach 1:
The PCB is divided into multiple layers with angled channels formed in specific layers, rather than attempting to cut through the entire board thickness. This segmentation allows angled connections to be created in the copper layers without compromising the structural integrity of the core PCB material.
Solution Approach 2:
The solution moves from two-dimensional edge cutting to three-dimensional channel formation within the PCB layers. By creating angled channels that extend through multiple layers and using vias to connect them, the patent achieves angular connections without cutting at the board edge, thus maintaining structural reliability.
2Adaptability or versatility
If edge cutting is performed on PCBs to achieve non-orthogonal angles, then the desired angular connection is achieved, but the mechanical strength of the PCB is compromised
Solution Approach 1:
The angled connection is segmented into channel portions in different layers connected by vias, eliminating the need for continuous edge cutting. This preserves the mechanical strength of the PCB edge while achieving the desired angular connection through internal layer structures.
Solution Approach 2:
Vias serve as intermediary elements that connect the angled channels in different PCB layers. These vias allow the angular connection to be formed through the thickness of the PCB without requiring edge cuts, thus maintaining the mechanical strength of the board edge.
3Adaptability or versatility
If special milling heads or machines are used to create non-orthogonal angles, then the desired angular connection is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses standard PCB manufacturing equipment and processes that can create angled channels and vias in multiple layers. These standard tools are made multi-functional by combining them to achieve angular connections, eliminating the need for specialized milling heads or machines while maintaining angular connection capability.
Solution Approach 2:
The angled channels and vias are pre-formed in the PCB layers during standard manufacturing processes before final assembly. This preliminary formation of connection paths allows standard equipment to achieve complex angular connections without requiring special tools during the actual connection process.
Data Source
AI summary
A method of fabricating components for a three-dimensional circuit structure includes providing a printed circuit board (PCB) having a top surface, an opposing bottom surface, and an end section. A first angled channel is formed in the top surface at the end section, with the first angled channel extending to an edge of the end section and dividing the end section into a first end portion and a second end portion. The PCB material is removed from the top surface at the first end portion to form a first support member having an upper surface at a preselected distance below the top surface. A second angled channel is formed in the bottom surface at the end section of the first PCB, with the second angled channel extending to the edge of the end section and being adjacent to the first support member. The PCB material is removed from the bottom surface at the second end portion to form a second support member having an upper surface that is contiguous with the top surface of the PCB. A ramp portion extends between the first support member and the second support member.