Rigid Flex PCB Cavity for Electronic Component Protection
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Solution Overview
Problem
Current display panel packaging technologies, such as COG and COF, face challenges in providing mechanical integrity and electrical protection for electronic components like TCON, especially in terms of pitch-matching and space constraints, leading to reduced display performance.
Innovation Solution
A rigid flex printed circuit board with a flexible inner core and outer stack-up layers, featuring a cavity that exposes the core for direct mounting of electronic components, allowing for pitch-matching with display panels and enhanced mechanical and electrical protection through a flexible metal routing layer and shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic components are mounted on the contact ledge or flex circuit in traditional COG/COF packaging, then electrical connection to display panel is achieved, but mechanical integrity and electrical protection are insufficient
Solution Approach 1:
The patent merges the flex circuit with a rigid PCB by forming a rigid flex PCB where the flex circuit is bonded to a rigid PCB, creating a hybrid structure that provides both flexibility and mechanical rigidity. This combined structure houses electronic components within a cavity formed in the rigid PCB, providing mechanical protection and electrical shielding while maintaining the electrical connection function.
Solution Approach 2:
The patent employs composite material construction by combining flexible and rigid materials in a single structure. The rigid flex PCB consists of a flex circuit bonded to a rigid PCB, creating a composite structure that leverages the flexibility of the FPC and the mechanical strength of the rigid PCB to provide both electrical connection and mechanical protection for electronic components.
2Manufacturing precision
If traditional PCB routing is used, then electrical connection is established, but pitch-matching with display panel contacts is difficult
Solution Approach 1:
The patent applies local quality by creating a cavity in the rigid PCB that exposes the flexible inner core, allowing electronic components to be mounted directly on the flexible routing layer. This localized modification enables precise pitch-matching with display panel contacts while maintaining ease of manufacture through standard PCB fabrication processes.
3Area of stationary object
If electronic components are mounted on flexible circuit, then space requirements are reduced, but mechanical protection and electrical shielding are insufficient
Solution Approach 1:
The patent implements nesting by placing electronic components within a cavity formed in the rigid PCB, where the cavity exposes the flexible inner core. This nested configuration allows components to be housed within the PCB structure itself, providing mechanical protection and electrical shielding while maintaining compact space requirements.
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 configuration provides improved mechanical integrity and electrical protection, enabling finer pitch trace routing and direct bonding of components, which enhances video signal quality and reduces space requirements, addressing the limitations of traditional PCBs and COF packaging.
Implementation Method 1
A flexible metal routing layer can be used to connect an electronic component to a display panel
Implementation Method 2
The distal end of the flexible area is bonded to a display panel
Data Source
AI summary
A rigid flex printed circuit board (PCB), method of manufacture, and display system incorporating the same are described. In an embodiment, a rigid flex PCB includes a flexible area extending from an adjacent routing area that is thicker than the flexible area. A flexible inner core spans the flexible area and the adjacent routing area. Outer stack-up layers are on the flexible inner core in the adjacent routing area. A cavity is formed in the outer stack-up layers in the routing area and exposes the flexible inner core. In an embodiment, a display system including such a circuit board may include an electronic component mounted on the flexible inner core within the cavity, and a distal end of the flexible area is bonded to a display panel.