Repairable Printed Circuit with Segmented Connection Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing parts with printed electronic circuits bonded to composite materials face damage issues, leading to costly replacements and waste, especially in applications where complete part change is not feasible or practical.
Innovation Solution
Incorporating connection terminals with larger cross-sections on conductive lines, allowing for the integration of a repair circuit segment that can replace faulty sections, facilitated by a method involving detection, exposure, and connection of repair modules with flexible conductive wires and optional heating systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If connection terminals with larger cross-sections are incorporated on conductive lines, then the ease of repair is improved by enabling repair circuit segments to connect and replace faulty sections, but the device complexity increases due to additional terminal structures and repair infrastructure
Solution Approach 1:
The electronic circuit is divided into multiple circuit segments separated by connection zones. Each connection zone contains connection terminals that enable independent segmentation of the circuit. When a fault occurs in one segment, only that segment needs to be repaired or replaced, not the entire circuit. This segmentation approach directly enables the repair functionality while managing complexity through modular design.
Solution Approach 2:
Connection terminals serve as intermediary elements between the conductive lines and the repair circuit segment. These terminals with larger cross-sections provide standardized connection points that facilitate the attachment of repair modules. The terminals act as mediators that enable external repair equipment to interface with the embedded circuit without requiring complex reconfiguration of the entire system.
2Reliability
If the conductive lines are printed with the smallest possible cross-section to optimize circuit functionality, then the electrical performance is improved, but the ease of repair deteriorates because faulty sections cannot be easily accessed or replaced
Solution Approach 1:
The circuit design employs different cross-section characteristics in different locations: the conductive lines maintain minimal cross-section for optimal electrical performance, while the connection terminals incorporate larger cross-sections specifically at connection zones. This local differentiation allows the circuit to achieve both excellent electrical properties and repairability, as the enlarged terminals provide accessible connection points without compromising the fine-line circuit performance.
3Reliability
If complete part replacement is performed when the electronic circuit is damaged, then the reliability is restored, but the loss of substance increases due to waste from discarding functional components and the high cost of replacement
Solution Approach 1:
The invention extracts only the faulty circuit segment from the complete electronic circuit for replacement, rather than replacing the entire part. The connection terminals and zones enable the faulty segment to be isolated and removed, while the remaining functional segments stay in place. This extraction approach restores reliability by replacing only what is necessary, significantly reducing material waste and associated costs.
Solution Approach 2:
The repair methodology discards only the damaged circuit segment while recovering and retaining all functional components, connection zones, and terminals. This selective discarding approach minimizes waste by keeping reusable elements in the system, contrasting with complete replacement where all components are discarded regardless of their functional status.
Data Source
AI summary
A part comprising a body and a film bonded to a surface of the body and incorporating an electronic circuit. This electronic circuit comprises at least one electronic component, conductive lines connected to the electronic component and at least two connection terminals positioned on at least one of the conductive lines, each connection terminal having a cross-section, in a plane parallel to the surface of the body, greater than twice the cross-section of a conductive line. By virtue of the connection terminals, which are distributed over the electronic circuit, it is possible to replace a faulty circuit segment with a repair circuit segment.