Rigidized Flexible PCB Layout for Compact Electronic Smoking Devices
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Solution Overview
Problem
Flexible printed circuit boards (PCBs) used in electronic smoking devices lack sufficient flexibility to fit within the anatomically shaped, compact housings, such as those resembling classic cigarettes, without compromising their functional integrity.
Innovation Solution
A rigidized flexible PCB design featuring spaced rigidizing zones with conductive tracks on a common flexible carrier, supported by first and second rigidizing layers, allowing for the attachment of electrical and electronic components, and enabling the PCB to be bent up to 180° without breaking, with conductive tracks connecting components across zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible printed circuit board is used to fit within compact anatomically shaped housings, then the flexibility and adaptability are improved, but the structural support and rigidity for mounting components deteriorate
Solution Approach 1:
The PCB structure implements local quality by creating distinct rigidized zones at specific locations where components need support, while the remaining portions of the flexible carrier maintain their flexibility. This is achieved by applying rigidizing layers selectively to certain areas of the flexible PCB, allowing different regions to have different mechanical properties - rigid where needed for component mounting, and flexible where needed for adaptation to housing shapes.
Solution Approach 2:
The invention uses composite materials by combining a flexible carrier material with rigidizing layers to create a hybrid structure. The flexible carrier provides bendability and adaptability, while the rigidizing layers provide structural support and stiffness. This composite construction allows the PCB to simultaneously exhibit both flexible and rigid characteristics in different regions, resolving the contradiction between flexibility and structural support.
2Volume of moving object
If the flexible PCB is made thinner to fit in compact devices, then the volume and size are reduced, but the mechanical strength and durability deteriorate
Solution Approach 1:
The thin flexible PCB maintains its small size overall while incorporating localized rigidized zones that provide enhanced mechanical strength where components are mounted. The rigidizing layers are applied only in specific areas rather than throughout the entire PCB, allowing the overall thickness to remain minimal for compact housing fitment while providing sufficient strength at critical locations.
Solution Approach 2:
The composite structure combines a thin flexible carrier with strategically placed rigidizing layers. This allows the PCB to maintain a thin profile for compact device integration while the rigidizing layers provide the necessary mechanical strength and durability at component mounting locations, resolving the contradiction between size reduction and strength maintenance.
3Strength
If rigidizing layers are added to provide structural support, then the strength and component mounting capability are improved, but the flexibility and bendability deteriorate
Solution Approach 1:
The rigidizing layers are applied locally to specific zones of the flexible PCB rather than covering the entire surface. This localized application provides structural support and component mounting capability in areas where rigidity is needed, while leaving other areas of the flexible carrier uncovered and maintaining their full flexibility and bendability for adaptation to anatomically shaped housings.
Solution Approach 2:
The PCB is segmented into distinct functional zones: rigidized zones for component mounting and flexible zones for bending and adaptation. The rigidizing layers create discrete rigidized zones that are spatially separated from each other, allowing the flexible carrier to bend between these zones while providing structural support within them. This segmentation resolves the contradiction by allowing both rigid and flexible regions to coexist in the same structure.
Data Source
AI summary
A printed circuit board is configured to mechanically support a plurality of electrical and/or electronic components which are electrically connected via conductive tracks. At least some of the conductive tracks are arranged on a common flexible carrier. A first rigidizing layer including a first rigidizing material is located at a first portion of a surface of the common flexible carrier to form a first rigidized zone. A second rigidizing layer including a second rigidizing material is located at a second portion of the surface of the common flexible carrier to form a second rigidized zone. The first portion of the surface and the second portion of the surface are spaced apart from each other. The first rigidizing material and the second rigidizing material support electrical and/or electronic components. The electrical, electronical components and/or conductor tracks are attached between the rigidizing layers.