Temporary PCB Rails with Reusable Interlocking Panel Support
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Solution Overview
Problem
The high cost and waste associated with large-scale PCB production due to the inclusion of excess PCB base material in the form of rails, which are discarded after panelization, amounting to 10%-30% of the total cost.
Innovation Solution
A system utilizing a panel with interlock lengths configured to interlock with non-PCB rail elements, featuring projections and recesses that allow the panel to be securely attached and detached without damaging the PCB, reducing the need for PCB material in the rail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PCB material is used to form rails for panelization, then the panel can be securely integrated into assembly machinery and protected during processing, but the cost of PCB production increases due to discarded rail material amounting to 10%-30% of total cost
Solution Approach 1:
The rail function is extracted from the PCB material and assigned to a separate support structure. The PCB panel is removed from the rail after assembly, allowing the rail to be reused while the PCB is discarded. This separates the reusable support function from the disposable product material.
Solution Approach 2:
The material composition of the rail is changed from PCB material to reusable non-PCB materials such as metal, plastic, or composite materials. This parameter change allows the rail to be reused across multiple production cycles, eliminating the waste of PCB material while maintaining structural integrity and secure integration capabilities.
2Extent of automation
If traditional PCB rails are used for panelization, then automated assembly can be achieved, but material waste increases significantly
Solution Approach 1:
The system is segmented into two distinct components: the reusable rail structure and the disposable PCB panel. The rail contains features like recesses, grooves, or slots that interface with corresponding features on the PCB, allowing automated handling while enabling separation after assembly. This segmentation allows the rail to be reused across multiple panels.
Solution Approach 2:
The rail acts as an intermediary carrier that temporarily holds the PCB during automated assembly processes. The rail provides the necessary mechanical interface for automated equipment while not being consumed in the process. After the PCB is assembled and removed, the rail remains intact for reuse with the next panel.
3Device complexity
If PCB material is used for rails, then the panel structure is simple and integrated, but production costs increase due to material waste
Solution Approach 1:
The rail is designed as a universal support structure that can accommodate multiple different PCB panels through standardized interfaces. The rail performs multiple functions: providing structural support, enabling automated handling, and serving as a reusable carrier. This universality allows one rail to serve many panels, reducing overall material consumption.
Data Source
Figure 1
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Figure 2B
AI summary
A system is disclosed. The system includes a panel (302) comprising a printed circuit board (PCB) (112) and a first panel side (320) comprising a first interlock length (316) configured to interlock with a first rail element (332). The first interlock length includes a projection (324) that interlocks within a corresponding recess (328) of the first rail element, wherein the first interlock length is configured to interlock with the first rail element and be removed from the first rail element without damaging the PCB or the projection. The system may further include the first rail element.