Programmable PCB With Electrowetting Traces for Rapid Prototyping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional PCB prototyping is time-consuming and costly, requiring weeks or months for fabrication and shipping of static prototypes, and involves high environmental impact due to multiple iterations.
Innovation Solution
A programmable circuit board (DPCB) that dynamically and reversibly defines PCB analogs by selectively moving droplets of working metal to unit cells using a rig with driver elements and substrates, enabling rapid prototyping and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional PCB prototyping is used, then manufacturing precision is achieved, but productivity is poor due to weeks or months fabrication time
Solution Approach 1:
The patent creates a digital twin or virtual model of the PCB that can be tested and validated in simulation before physical fabrication. This virtual copy allows for rapid iteration and testing without the time-consuming physical manufacturing cycle, resolving the contradiction between achieving manufacturing precision and improving productivity.
Solution Approach 2:
The patent performs design validation, testing, and verification in the virtual model before committing to physical fabrication. This preliminary action in the digital domain prevents costly rework and iterations in physical manufacturing, significantly reducing the overall prototyping time while ensuring manufacturing precision is achieved on the first physical attempt.
2Reliability
If multiple PCB prototype iterations are fabricated, then design validation is improved, but environmental impact worsens due to waste material
Solution Approach 1:
The patent uses a virtual model to perform multiple iterations of design validation, testing, and verification. These virtual iterations provide the same design validation accuracy as physical prototypes but generate zero manufacturing waste, directly resolving the contradiction between improving reliability through iterations and reducing environmental impact.
Solution Approach 2:
The patent discards the need for physical prototype iterations by recovering and utilizing the virtual model for repeated testing and validation. Instead of manufacturing and discarding physical prototypes, the system recycles the digital model through multiple validation cycles, eliminating waste while maintaining validation accuracy.
3Measurement precision
If physical PCB prototypes are manufactured and shipped, then testing accuracy is improved, but loss of time increases due to shipping delays
Solution Approach 1:
The patent creates a virtual model that replicates the electrical and functional characteristics of the physical PCB. This digital copy can be tested immediately without shipping delays, while still providing accurate test results that reflect the actual physical board's behavior, thus resolving the contradiction between measurement precision and time loss.
Solution Approach 2:
The patent introduces a virtual model as an intermediary between the design phase and physical fabrication. This intermediary allows for complete testing and validation before the physical board is manufactured, eliminating the need for rapid shipping and delivery while ensuring test accuracy is achieved on the first physical prototype.
4Productivity
If conventional prototyping is used, then manufacturing precision is achieved, but productivity is poor due to high costs and multiple iterations
Solution Approach 1:
The patent uses a virtual model to perform all possible design iterations, validations, and optimizations before physical fabrication. This digital copying approach eliminates the need for multiple expensive physical prototype iterations, significantly improving productivity while reducing manufacturing costs to a single fabrication run.
Solution Approach 2:
The patent performs all necessary design validation, testing, and optimization in the virtual model before committing to physical manufacturing. This preliminary action ensures that the single physical fabrication is correct the first time, eliminating rework costs and improving both productivity and ease of manufacture by reducing the total number of manufacturing iterations required.
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
Faster, less expensive, and environmentally friendly PCB prototyping and testing, allowing for minutes-to-hours design iterations with remote capabilities and similar test results as actual PCBs.
Implementation Method 1
the substrate and the electrowetting device are operable to selectively move droplets of the working metal to the unit cells in the array
Data Source
AI summary
A programmable circuit board, preferably including: a rig, a reservoir, and working metal, wherein the rig preferably includes a set of unit cells cooperatively defined by a stack of substrates and a set of driver elements. A method for dynamically programming a circuit board, preferably including: receiving a circuit board design; determining a unit cell map; positioning working metal; optionally assembling a remainder of circuit board components; optionally testing the assembled PCB analog; and/or optionally updating the physical PCB analog configuration.