PCB Strain Relief via Segmented Resilient Tabs
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Solution Overview
Problem
Printed circuit boards (PCBs) in vehicle applications experience high levels of strain at the interface with other components, which can lead to damage and cracking of the PCB and its connections, particularly around sensors secured with electrically conductive solder.
Innovation Solution
A strain relief mechanism is implemented using a plurality of overlapping, spaced-apart slots on the PCB that cooperate with its edges to form a resilient tab, redirecting strain away from sensors and preventing excessive stress on the PCB and solder connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the PCB is rigidly connected to other components, then connection strength is improved, but strain and stress on the PCB and solder joints increase
Solution Approach 1:
The PCB edge is segmented into multiple resilient tabs separated by slots, allowing each tab to independently accommodate strain while maintaining overall connection strength. The slots create discrete segments that can flex without compromising the integrity of the entire connection interface.
Solution Approach 2:
The connection interface is made dynamic through the resilient tabs that can flex and deform under strain. This dynamic capability allows the rigid PCB structure to accommodate movement and stress through controlled deformation of the tab regions, preventing stress concentration.
2Reliability
If sensors are secured with electrically conductive solder, then electrical connection is improved, but vulnerability to strain-induced damage increases
Solution Approach 1:
The resilient tabs provide beforehand cushioning by absorbing and redistributing strain before it reaches the solder joints. The slots create compliant regions that deform under stress, cushioning the protective effect on the soldered sensor connections and preventing strain-induced damage.
3Stress or pressure
If the PCB interface is made compliant to reduce strain, then stress on connections is reduced, but connection strength may be compromised
Solution Approach 1:
Compliance is introduced locally at the tab regions through the slots, while the rest of the PCB and sensor connections maintain their rigid, strong structure. This localized quality change allows strain absorption without compromising overall connection strength, as the compliant regions are confined to specific areas.
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
The strain relief effectively redistributes strain induced during connections, preventing damage to the PCB and its connections, ensuring the integrity of electronic components and secure attachment to other components.
Implementation Method 1
a strain relief including a plurality of overlapping, spaced-apart slots that cooperate with the at least one edge to define a resilient tab for redistributing strain induced in the printed circuit board
Data Source
AI summary
An electronic device includes a printed circuit board having at least one edge and a strain relief including a plurality of overlapping, spaced-apart slots that cooperate with the at least one edge to define a resilient tab for redistributing strain induced in the printed circuit board.