PCB Core Slot Design for Connection Tab Integration
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Solution Overview
Problem
The challenge is to miniaturize the size of a printed circuit board (PCB) while maintaining the accommodation of all necessary components and enhancing protection, quality, and reliability, particularly in radio batteries where space is constrained by the need for numerous connection tabs and spot welding requirements, leading to increased costs and reduced real estate for component placement.
Innovation Solution
The solution involves creating a PCB with plated-through holes and a core section, where the core section is shorter than the outer layers, allowing for an open slot to house connection tabs, reducing the space required for spot welding and enabling more components to be housed on the board, and eliminating the need for welding tabs and associated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spot welding is used to connect connection tabs to contacts, then reliable electrical connection is achieved, but significant PCB space (84 mm² per tab plus keep-out area) is consumed
Solution Approach 1:
The patent extracts the welding tab functionality from the PCB by using separate connection tabs that are mechanically attached to the PCB surface rather than being integrated into the PCB substrate. This separation allows the PCB to maintain its structural integrity while connection tabs provide the electrical connection function, significantly reducing the space required on the PCB surface.
Solution Approach 2:
The connection tabs are designed to nest within the keep-out areas or alongside existing PCB features, maximizing space utilization. The tabs are positioned to utilize otherwise wasted space around plated-through holes and along PCB edges, allowing multiple tabs to be accommodated in minimal area.
2Area of stationary object
If multilayer PCB is used to accommodate all components and traces, then component placement space is increased, but manufacturing cost increases
Solution Approach 1:
The patent utilizes the third dimension (vertical stacking) by employing plated-through holes that pass through the PCB layers, allowing electrical connections to be made between components on different sides of the PCB without requiring additional lateral space. This enables efficient routing of signals and power between battery cells and electronic components using through-hole technology rather than requiring expanded planar area.
3Reliability
If connection tabs are spot welded to contacts, then electrical connection is established, but welding-related defects (misalignment, overhanging, placement errors) occur
Solution Approach 1:
The patent replaces the welding process with a mechanical attachment system where connection tabs are physically secured to the PCB surface through friction fit, adhesive bonding, or mechanical retention features integrated into the PCB structure. This eliminates the need for precise welding alignment and removes sources of welding-related defects such as splatter, cold joints, and dimensional inaccuracies.
4Area of stationary object
If PCB size is reduced to minimize product size, then portability is improved, but space for connection tabs and keep-out areas becomes insufficient
Solution Approach 1:
The connection tabs are designed with flexible mounting mechanisms that allow them to be securely attached to the PCB surface without requiring large rigid keep-out areas. The tabs can conform to the PCB surface and maintain reliable electrical connections even in compact configurations, enabling reduced PCB size while preserving connection integrity.
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 reduces the PCB size, eliminates the need for costly multilayer boards, and enhances reliability and robustness by allowing more space for components, improving assembly efficiency, and reducing impedance and mechanical tolerances, resulting in a more reliable and cost-effective PCB.
Implementation Method 1
The printed circuit board includes at least one plated-through hole via drilled into at least one of a first layer on a first side of the printed circuit board and a second layer on a second side of the printed circuit board
Data Source
AI summary
A printed circuit board includes at least one plated-through hole via drilled into at least one of a first layer on a first side of the printed circuit board and a second layer on a second side of the printed circuit board. The printed circuit board also includes a core section laminated between the first layer and the second layer, wherein a length of the core section is shorter than a length of the first layer and a length of the second layer. The printed circuit board further includes an open slot configured to house a connection tab of an electronic product connected to the printed circuit board, wherein the open slot is formed adjacent to the core section and between sections of the first layer and the second layer that are longer than the core section.