Polymer Flex Board Spacer with Orifices for Crack Resistance
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Solution Overview
Problem
Conventional metal sleeves used as spacers on flex boards for aircraft electronics often crack, leading to connector damage and inadequate support, and are not economically viable.
Innovation Solution
A spacer made from a non-conductive material using additive manufacturing, with a monolithic, integral structure and asymmetrical portions, providing support at multiple distinct locations and featuring orifices for attachment, to prevent connector crushing and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal sleeves are used as spacers on flex boards, then the spacers provide structural support, but they crack during use leading to connector damage
Solution Approach 1:
The patent changes the material parameter from metal to polymer, fundamentally altering the mechanical properties. This transition provides crack resistance and flexibility while maintaining support capability through the polymer's inherent toughness and ability to deform without fracturing like metal
Solution Approach 2:
The spacer is formed as a composite structure combining multiple polymer materials - a rigid polymer for structural support and a flexible polymer for crack resistance. This composite approach allows the spacer to simultaneously provide strength and reliability
2Strength
If metal sleeves are used as spacers, then support is provided, but manufacturing costs increase and economic viability decreases
Solution Approach 1:
The spacer integrates multiple functions into a single component: structural support, connector protection, and positioning features. This merging eliminates the need for separate metal sleeves and additional assembly steps, reducing manufacturing complexity and cost
Solution Approach 2:
Changing from metal to polymer material enables more economical manufacturing through processes like injection molding, which are generally more cost-effective than metal fabrication and assembly for this type of component
3Stability of the object's composition
If the spacer contacts boards at multiple locations, then support and stability are enhanced, but the spacer design becomes more complex
Solution Approach 1:
The spacer utilizes three-dimensional positioning with contact points distributed across different spatial locations. This dimensional approach provides stable support at multiple locations while maintaining a relatively simple overall geometry that can be manufactured as a single piece
Data Source
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AI summary
A spacer (100) for providing support to a flex board including a spacer body having, a first portion (114) including multiple surfaces on a first side thereof and multiple surfaces on a second side opposite the first side, a second portion (116) including multiple surfaces on a first side thereof and multiple surfaces on a second side opposite the first side, wherein the second portion is connected to the first irregular portion by a bridge (122) having a single surface on a first side thereof and multiple surfaces on a second side opposite the first side and a set of orifices (126/130) each for receiving a fastener therein, wherein at least one of the orifices is located on the first side of the first portion and at least one of the orifices is located on the first side of the second portion.