Rigid PCB Bend Region for Curved Antenna Integration

Solution Overview

Problem

Existing rigid printed circuit boards face challenges in matching antennas to curved contours without the need for flexible materials, which are more expensive.

Innovation Solution

A printed circuit board design featuring a bend region with narrowing and through holes allows bending, enabling it to conform to curved surfaces, with an antenna arranged in this region to match the contour.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If flexible printed circuit boards are used to match antenna to curved contour, then antenna matching to contour is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecurved contour matchingVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The printed circuit board has different properties in different regions: rigid regions for structural support and a bend region with reduced thickness (through holes and narrowing) for flexibility. This local differentiation allows the board to be rigid where needed and flexible where needed to match curved contours, resolving the contradiction between shape adaptability and manufacturing cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The printed circuit board is segmented into multiple regions with different mechanical properties: first and third regions that are rigid, and a middle bend region that is flexible. This segmentation allows the antenna to match curved contours while using cost-effective rigid board materials for the majority of the structure.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If rigid printed circuit boards are used, then manufacturing cost is reduced, but ability to match curved contour is worsened

Engineering Contradiction:

Improvemanufacturing costVSAvoidcurved contour matching

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The printed circuit board has different properties in different regions: rigid regions for structural support and a bend region with reduced thickness (through holes and narrowing) for flexibility. This local differentiation allows the board to be rigid where needed and flexible where needed to match curved contours, resolving the contradiction between shape adaptability and manufacturing cost.

Inventive Principle:

Principle #3Local quality

3Shape

If printed circuit board is bent, then curved contour is achieved, but structural integrity may be compromised

Engineering Contradiction:

Improvecurved contourVSAvoidstructural integrity

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The printed circuit board is segmented into multiple regions with different mechanical properties: first and third regions that are rigid, and a middle bend region that is flexible. This segmentation allows the antenna to match curved contours while using cost-effective rigid board materials for the majority of the structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bend region is pre-designed with through holes and narrowing during manufacturing, creating a predetermined flexible zone that will bend at the intended location and angle. This preliminary preparation ensures that when the board is installed on the curved surface, it bends in the correct region without compromising the structural integrity of the rigid portions.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12590476B2Bending printed circuit boards

Publication Date: 2026.03.31 HELLA GMBH & CO KGAA

AI summary

A printed circuit board having essentially a first region, a second region, and a third region. The first region and the third region can be used for the placement of electrical and/or electronic components. The second region located in the middle of the three regions is a bend region. A side edge of the printed circuit board is offset inward in this region in order to narrow the contour of the printed circuit board in the bend region. This region likewise has one or more through holes. Both the narrowing and the through holes facilitate a bending of the printed circuit board, namely a bending of the first region relative to the third region or vice versa.