Multi-piece PCB Replacement Using UV Curing Adhesive
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Solution Overview
Problem
Existing multi-piece boards with frames and printed wiring parts face challenges in efficiently replacing defective pieces without wasting good pieces and ensuring strong adhesion between frames and pieces, leading to issues with yield and reliability.
Innovation Solution
A fabrication method involving checking for defective pieces, forming recesses and projections, fitting good pieces into corresponding recesses, flattening joint portions, and filling UV curing adhesive to secure the frames and pieces, which enhances connection strength and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If defective pieces are replaced by cutting and attaching new pieces, then yield is improved, but connection strength between frame and piece deteriorates
Solution Approach 1:
Recesses and projections are formed in advance during the board fabrication process before any replacement occurs. This preliminary preparation ensures that when pieces need replacement, the structural features for strong connection already exist, eliminating the need for weakening cuts during replacement operations.
Solution Approach 2:
The joint portions between frame and pieces are given special local structural features (recesses and projections) that provide enhanced connection strength specifically at these critical interfaces, while the rest of the board maintains its standard structure for ease of replacement.
2Ease of repair
If pieces are replaced by cutting and attaching, then defective pieces can be removed, but manufacturing precision deteriorates
Solution Approach 1:
The recesses and projections are formed with precise dimensions during the initial board fabrication using standard manufacturing processes. This preliminary precision work ensures that subsequent replacement operations can be performed easily without requiring high-precision cutting or alignment operations.
Solution Approach 2:
The recesses and projections act as intermediary structural features that mediate between the frame and replacement pieces. These pre-formed features serve as guides and mechanical interlocks that automatically ensure precise alignment and positioning during replacement, eliminating the need for high-precision manual alignment.
3Strength
If adhesive is applied to join frame and piece, then connection strength is improved, but air bubbles in adhesive reduce reliability
Solution Approach 1:
Recesses are formed specifically in the joint portions where adhesive will be applied. These localized recesses concentrate the adhesive in controlled areas, ensuring complete filling without trapping air bubbles, while the rest of the board surface remains flat for other purposes.
Solution Approach 2:
The recesses create a vertical dimension in the joint portions, allowing adhesive to be contained and compressed into a thin, bubble-free layer. This dimensional feature ensures the adhesive fills the joint completely from above without air entrapment, while maintaining a flat overall board surface.
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 method allows for efficient replacement of defective pieces, improving yield and connection strength between frames and pieces, reducing waste and ensuring high reliability in electronic part mounting.
Implementation Method 1
filling a UV-curing adhesive in a recess and curing the adhesive to adhere the frame and good piece
Data Source
AI summary
A fabrication method for a multi-piece board includes: checking whether pieces (printed wiring boards) are defect-free or not; forming a first recess in a joint portion between a defective piece and a frame; forming a first fitting portion at the frame by separating the defective piece; cutting out a defect-free piece having a second fitting portion from another board; forming a second recess in the second fitting portion; fitting the second fitting portion into the first fitting portion; flattening a joint portion; and filling an adhesive in a third recess which is formed by the first recess and the second recess, and curing the adhesive to adhere the frame and the defect-free piece.