Rigid-Flex Component Carrier Step Feature Stress Management

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Solution Overview

Problem

Rigid-flex component carriers face mechanical stress issues during bending, leading to potential breakage and reduced lifetime due to high mechanical loads at the transition between rigid and flexible portions, particularly at corners where tensile forces are applied.

Innovation Solution

Incorporating a step feature in the cavity at the transition region between the rigid and flexible portions, which redirects tensile forces into compressive forces, enhancing mechanical integrity and reducing the risk of breakage by distributing stress more effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a rigid-flex component carrier is bent, then the component carrier can accommodate flexible routing requirements, but high mechanical load is generated at the transition between rigid and flexible portions leading to potential breakage and reduced lifetime

Engineering Contradiction:

Improveflexible routing capabilityVSAvoidmechanical reliability at transition region

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The cavity is segmented into multiple levels by introducing at least one step, creating a multi-level structure that divides the transition region. This segmentation allows the cavity to better accommodate the dimensional mismatch between rigid and flexible portions, distributing mechanical stress across multiple surfaces and reducing peak loads at any single location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The step feature modifies the local geometry of the cavity at the transition region, creating a multi-level structure with different heights. This local quality change allows the cavity to provide optimized support specifically where mechanical stress is highest, while maintaining the overall rigid-flex functionality of the component carrier.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the cavity is made deeper to increase flexibility, then flexible portion movement is improved, but tensile forces at corners increase leading to higher risk of breakage

Engineering Contradiction:

Improveflexible portion flexibilityVSAvoidresistance to tensile forces at corners

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The step feature introduces a vertical dimension variation within the cavity structure, creating a multi-level configuration. This dimensional change allows the cavity to provide flexible support while the stepped surfaces redirect tensile forces into compressive forces, converting the nature of the mechanical load and reducing the risk of corner breakage.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If a step feature is added to the cavity, then mechanical robustness is improved by redirecting forces, but device complexity increases

Engineering Contradiction:

Improvemechanical robustnessVSAvoidcavity structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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 step feature significantly increases the force required to cause failure, improving the mechanical robustness and longevity of the component carrier by converting tensile stress into compressive stress, thus preventing damage during bending and mechanical loading.

Implementation Method 1

the step feature significantly increases the force required to cause failure, improving the mechanical robustness and longevity of the component carrier by converting tensile stress into compressive stress

Methodology Applied

Scientific EffectForce redirection:

Data Source

PatentUS11324126B2Mechanically robust component carrier with rigid and flexible portions

Publication Date: 2022.05.03 AT & S AUSTRIA TECHNOLOGIE & SYSTEMTECHNIK AG

AI summary

A component carrier with a rigid portion, a flexible portion, a cavity defining the flexible portion next to the rigid portion, and at least one step in a transition portion between the rigid portion and the flexible portion in the cavity is disclosed.