PCB Support Bracket Assembly for Cost Reduction
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Solution Overview
Problem
The existing methods for installing printed circuit boards (PCBs) in devices or vehicles require enlarging the PCB size and shaping it irregularly for mechanical attachment, leading to wastage of material and increased manufacturing costs due to the need for additional attachment areas made of expensive materials like fiber glass and copper.
Innovation Solution
A support bracket made of a less expensive material, such as plastic or light metallic materials, is designed to attach the PCB to an external structure, allowing the PCB to be fabricated with regular shapes and optimizing material usage, while the support bracket also aids in heat dissipation and ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the PCB area is enlarged to include attachment areas for mechanical fastening, then the PCB can be securely attached to the apparatus, but the amount of expensive PCB material (fiber glass and copper) is increased
Solution Approach 1:
The apparatus is segmented into two functional parts: the PCB containing only the electronic circuit, and a separate support bracket for mechanical attachment. This segmentation allows each component to be optimized independently, with the PCB using minimal material for its electronic function and the support bracket providing the necessary mechanical strength for attachment.
Solution Approach 2:
A support bracket acts as an intermediary component between the PCB and the apparatus structure. This mediator provides the mechanical attachment function without requiring the PCB itself to be enlarged, thus protecting the PCB from structural stresses and preventing material waste.
2Adaptability or versatility
If the PCB shape is made irregular to accommodate attachment areas, then the PCB can be attached to specific parts of the apparatus, but material waste from mother board planks increases
Solution Approach 1:
The attachment function is segmented from the PCB and transferred to a separate support bracket. This allows the PCB to maintain a regular, optimized shape for efficient material utilization from mother board planks, while the support bracket provides the irregular geometry needed for attachment to specific apparatus locations.
Solution Approach 2:
The support bracket is made from inexpensive material that can be easily manufactured and discarded if needed. This allows for flexible, irregular shapes optimized for attachment without the economic penalty of wasting expensive PCB materials, as the bracket serves as a disposable or replaceable attachment interface.
3Strength
If additional board material is used for attachment areas, then the PCB can be mechanically fastened to the apparatus, but manufacturing costs increase
Solution Approach 1:
The mechanical fastening function is segmented from the expensive PCB and assigned to a separate support bracket made from cheaper material. This reduces manufacturing costs by using appropriate materials for each function: the PCB uses expensive materials only where electronically necessary, while the support bracket provides mechanical strength at lower cost.
Solution Approach 2:
The support bracket serves as an intermediary that provides mechanical fastening capability without requiring additional expensive PCB material. This mediator component reduces overall manufacturing costs while maintaining the necessary attachment strength to the apparatus.
4Strength
If the PCB area is increased to provide attachment surfaces, then the PCB can be secured to the apparatus, but the weight of the assembly increases
Solution Approach 1:
The attachment function is segmented from the PCB and transferred to a separate support bracket. This allows the PCB to maintain its minimal, optimized weight for electronic functionality, while the support bracket provides the necessary attachment security without adding excessive weight to the overall assembly.
Solution Approach 2:
The support bracket acts as an intermediary that provides attachment security without requiring the PCB itself to be enlarged and thereby weighted down. This mediator component optimizes the weight distribution, keeping the PCB lightweight while still achieving secure attachment to the apparatus.
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 solution reduces manufacturing costs and simplifies the PCB fabrication process by minimizing material waste and allowing for optimized material usage, while enhancing heat dissipation and ventilation through the PCB assembly.
Implementation Method 1
the printed circuit board has a heat sink arranged to be in contact with the metallic part of the support bracket, such that heat can be transferred from the heat sink to the metallic part of the support bracket to enhance heat dissipation
Data Source
Figure 1~2
Figure 3
AI summary
The invention refers to a support bracket assembly for printed circuit boards (PCB's). The assembly comprises a support bracket having attaching means configured to allow the attachment of the support bracket to an external structure, and a printed circuit board. The assembly further includes coupling means for mechanically coupling the support bracket and the printed circuit board together, such that the printed circuit board is supported and retained by the support bracket. With the assembly of the invention, the printed circuit board can be supported and attached to an external structure by means of the support bracket, so that, there is no need to have some parts of the board of the printed circuit board dedicated solely for its attachment. In this way, the invention reduces PCB's manufacturing costs, by reducing PCB material and simplifying PCB's contour.