Stacked PCB Assembly With Interposer Contacts for Compact Motor Drivers
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Solution Overview
Problem
Conventional stacked circuit boards connected via male/female electrical connectors face space constraints, increased material costs, and labor-intensive manual assembly, hindering size reduction and productivity.
Innovation Solution
A stacked circuit board assembly with a third circuit board positioned between two main circuit boards, utilizing electrical contacts on opposite sides connected by a conductive structure, replacing traditional connectors, allowing for automated assembly and reduced size and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If male/female electrical connectors are used to connect stacked circuit boards, then electrical connection is achieved, but the overall size increases and material cost increases
Solution Approach 1:
The patent extracts and removes the traditional male/female electrical connector structure from the circuit board assembly. Instead of using separate connector components, the electrical connection is achieved through direct contact between corresponding contact structures on adjacent circuit boards, eliminating the need for bulky connector housings and reducing overall assembly size.
Solution Approach 2:
The patent merges the electrical connection function with the circuit board structure itself. The contact structures are integrated directly into the circuit board layers, combining the functions of electrical connection and structural support into a single unified design, thereby eliminating separate connector components.
2Reliability
If male/female electrical connectors are used to connect stacked circuit boards, then electrical connection is achieved, but material cost increases
Solution Approach 1:
The patent removes the expensive connector materials (metal contacts, plastic housings, insulation materials) from the design. Electrical connection is achieved using simple conductive traces and contact structures that are part of the standard circuit board fabrication process, significantly reducing material costs.
Solution Approach 2:
The patent uses cost-effective conductive materials and standard circuit board fabrication techniques instead of expensive connector components. The electrical connection structures are created using standard PCB manufacturing processes, which are more economical than assembling separate connector parts.
3Reliability
If male/female electrical connectors are used to connect stacked circuit boards, then electrical connection is achieved, but manual assembly is required making production time-consuming
Solution Approach 1:
The patent combines the electrical connection structures with the circuit board manufacturing process itself. The contact structures are created during standard PCB fabrication, meaning the electrical connections are built-in and require no separate assembly steps, enabling automated production and significantly improving productivity.
Solution Approach 2:
The electrical connection structures are prepared and integrated into the circuit boards during the manufacturing process before the boards are assembled into the final stacked configuration. This preliminary integration of connection structures eliminates the need for manual connector assembly during production.
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 new design reduces size and material costs while enabling automated production, improving productivity and allowing space for thermal management components.
Implementation Method 1
The conductive connection structure connects the third electrical contact to the fourth electrical contact
Data Source
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AI summary
A stacked circuit board assembly includes a first circuit board, a second circuit board alongside the first circuit board, and a third circuit board disposed between the first and second circuit boards. The first circuit board includes a first electrical contact, and the second circuit board includes a second electrical contact. The third circuit board includes a substrate, a third electrical contact, a fourth electrical contact and a conductive connection structure. The third and fourth electrical contacts are disposed on two opposite surfaces of the substrate, respectively, and are attached to the first and second electrical contacts, respectively. The conductive connection structure connects the third electrical contact to the fourth electrical contact.