Speaker Box Flexible Circuit Board Single-Sided Assembly
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Solution Overview
Problem
The manufacturing process for speaker boxes is complicated and costly due to the need to bend a flexible circuit board 180 degrees, which weakens the circuit board's overall strength and increases production expenses.
Innovation Solution
A speaker box design featuring a housing with a through hole and a flexible circuit board with a bending part that connects both pads on the same surface, allowing for a single-sided circuit board assembly that simplifies manufacturing, enhances stability, and reduces costs by eliminating the need for 180-degree bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flexible circuit board is bent 180 degrees during assembly to expose the pad outside the housing, then the pad can be electrically connected to external circuits, but the overall strength of the flexible circuit board is weakened and the manufacturing process becomes complicated
Solution Approach 1:
The flexible circuit board transitions from a planar configuration to a three-dimensional structure with multiple bending sections. The board includes a first bending section that extends upward from the first mounting part, a second bending section that extends toward the cover, and a third bending section that extends toward the cover to reach the through hole. This multi-dimensional bending path allows the second pad to be exposed outside the housing through the through hole without requiring a single 180-degree bend, thereby maintaining structural strength while achieving electrical connection.
2Ease of operation
If the flexible circuit board is bent 180 degrees during assembly, then the pad can be exposed to outside the housing, but the manufacturing process becomes complicated and manufacturing cost increases
Solution Approach 1:
The flexible circuit board is pre-formed with multiple bending sections (first, second, and third bending sections) during the manufacturing process. These bending sections are预先 configured to guide the second pad through the through hole to the outside of the housing. By pre-forming the three-dimensional structure rather than requiring complex assembly-time manipulation, the manufacturing process is simplified while achieving the required pad exposure and electrical connection functionality.
3Reliability
If a double-sided flexible circuit board is used with 180-degree bending, then electrical connection can be achieved, but the assembly process becomes complicated and assembly efficiency decreases
Solution Approach 1:
The flexible circuit board is segmented into distinct functional parts: a first mounting part with a first pad for speaker unit connection, multiple bending sections (first, second, and third bending sections) for spatial transition, and a second mounting part with a second pad for external circuit connection. This segmentation allows each part to perform its specific function independently, simplifying the assembly process while maintaining reliable electrical connections between the speaker unit, external circuits, and housing.
Data Source
AI summary
A speaker box includes a housing, a speaker unit and a flexible circuit board. The housing includes a base defining a through hole, and a cover. The flexible circuit board includes an end received in the housing and an opposite end exposed to outside of the housing. The flexible circuit board includes a first surface facing the cover and a second surface opposite to the cover. A first pad and a second pad are disposed at the second surface. The flexible circuit board includes a first mounting part, a second mounting part and a bending part. The first pad is arranged on the first mounting part and configured to be electrically coupled to the speaker unit. The second pad is arranged on the second mounting part and configured to be electrically coupled to external circuits. The second pad is exposed to outside of the housing via the through hole.