Electrical Traces in Suspension Assemblies via Additive Manufacturing
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Solution Overview
Problem
The existing methods for creating electrical connections between electrical traces in suspension assemblies, such as those used in camera autofocus and optical image stabilization systems, are time-consuming and costly, especially in constrained routing spaces like thin foils, and do not fit well with mass-production manufacturing processes.
Innovation Solution
A technique involving the removal of parts of the suspension assembly to create cavities around conductive material, forming a bus bar, and filling trenches with conductive material to connect electrical traces, which can be integrated into an additive manufacturing process for improved precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods are used to create electrical connections in suspension assemblies, then manufacturing complexity is reduced, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent combines multiple manufacturing operations (creating cavities, forming bus bars, filling trenches with conductive material) into a single integrated additive manufacturing process. This merging of previously separate steps into one unified process directly reduces manufacturing time while managing complexity through process integration rather than multiplication of discrete operations.
Solution Approach 2:
The additive manufacturing process performs preliminary actions by depositing conductive material and forming electrical connections during the same manufacturing step that creates the suspension assembly structure. This eliminates the need for subsequent separate steps to create electrical connections, thereby reducing overall manufacturing time without requiring complex multi-step processes.
2Manufacturing precision
If existing methods are used to create electrical connections in constrained routing spaces, then process simplicity is maintained, but precision and quality control deteriorate
Solution Approach 1:
The additive manufacturing process enables local quality by precisely depositing conductive material only where needed to form electrical connections and bus bars in constrained routing spaces. This localized precision is achieved through the inherent capability of additive manufacturing to place material with high accuracy at specific locations, improving electrical connection precision without requiring complex tooling or multiple processing steps.
Solution Approach 2:
The patent replaces traditional mechanical methods of creating electrical connections (such as bonding, welding, or mechanical fastening) with an additive manufacturing process that deposits conductive material directly to form electrical paths. This substitution eliminates the need for separate mechanical connection steps, improving precision in constrained spaces while managing overall process complexity through integration.
3Productivity
If mass production is implemented with existing methods, then production volume increases, but manufacturing cost and time per unit increase
Solution Approach 1:
The patent merges structure fabrication and electrical connection creation into a single additive manufacturing process, eliminating the need for separate post-processing steps. This integration reduces the total number of manufacturing operations required per unit, thereby reducing both time and cost per unit while enabling mass production through efficient process consolidation.
Solution Approach 2:
The additive manufacturing process performs self-service by creating both the structural components and the electrical connections within the same manufacturing step. The system uses conductive material deposited during the additive process to automatically form bus bars and electrical traces, eliminating the need for separate electrical connection operations and reducing overall manufacturing cost and time per unit.
Data Source
AI summary
A camera may include at least one suspension assembly as part of optical image stabilization and/or autofocus systems of the camera. The suspension assembly may include an inner frame, an outer frame, and one or more flexure arms. Electrical traces may be deposited at both sides of the suspension assembly. A connection may be created, for electrical traces at the different sides of the suspension assembly, through the suspension assembly by removing (e.g., using an etching process) one or more parts in the body of the suspension assembly to create one or more cavities. A remaining part of the suspension assembly surrounded (and thus isolated) by the cavities may thus form at least a part of the connection for the electrical traces. The connection may further include one or more filled trenches connecting the electrical traces to the remaining part of the suspension assembly.