Thermoplastic Elastomer Coated Flexible Circuit Body
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Solution Overview
Problem
Conventional flexible wiring boards for robots are prone to damage and disconnection due to rubbing and external forces, leading to reliability issues and a short service life, especially in applications requiring expandable and contractible cables.
Innovation Solution
A flexible circuit body is developed with a thermoplastic elastomer coating on the wiring board, allowing it to maintain a predetermined shape and prevent wear, and can be laminated with a urethane elastomer for enhanced mechanical strength and wear resistance, which also shields against electric and magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible wiring board is shaped in a zigzag or coil shape to increase expandability and contractibility, then the degree of freedom in wiring is improved, but the wiring layer can be peeled off and disconnected and the flexible wiring board itself can be damaged by rubbing or external forces
Solution Approach 1:
The patent applies composite materials by combining the flexible wiring board (insulating film + wiring layer + insulating layer) with a thermoplastic elastomer coating. This composite structure provides both the flexibility needed for expansion and contraction and the protective properties to prevent damage from rubbing and external forces, thereby resolving the contradiction between adaptability and reliability
Solution Approach 2:
The thermoplastic elastomer coating is applied in advance to the flexible wiring board before it undergoes zigzag or coil shaping. This pre-applied protective layer acts as a cushion that prevents the wiring layer from peeling off and protects the board from damage during subsequent rubbing or exposure to external forces, maintaining connection reliability while preserving expandability
2Reliability
If an extra length part is provided in cables to prevent bending or breaking, then cable durability is improved, but a space for slacking the cable is required in the surrounding of the joint part
Solution Approach 1:
The patent employs a flexible wiring board that can dynamically expand and contract as needed, eliminating the need for static extra length parts. The board adapts its length based on the mechanical requirements of the robot joint, providing durability without requiring additional space for cable slacking
Solution Approach 2:
The flexible wiring board changes its physical parameters (length, shape) through elastic deformation rather than requiring fixed extra length. By utilizing the elastic properties of the insulating film and wiring structure, the board can extend and retract as needed, improving durability without increasing device complexity or space requirements
3Reliability
If a support rod is arranged at the position of the center of joint rotation to prevent cable damage, then cable protection is improved, but the demand for expandable and contractible cables increases
Solution Approach 1:
The flexible wiring board combines multiple materials (insulating film, wiring layer, insulating layer) with complementary properties. The insulating film provides structural support and flexibility, while the wiring layer provides electrical functionality, creating a composite structure that is both protected and adaptable without requiring a separate support rod
Solution Approach 2:
The flexible wiring board serves multiple functions simultaneously: it provides electrical connection, mechanical flexibility for expansion and contraction, and structural protection through its multi-layer construction. This multi-functionality eliminates the need for separate support rods while maintaining both cable protection and adaptability
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 solution provides a highly reliable, wear-resistant flexible circuit body that can maintain its shape and prevent peeling, ensuring reliable operation under mechanical stress and external forces, while reducing the need for extra cable length and improving connection reliability.
Implementation Method 1
heating to be performed on the flexible circuit body at a temperature equal to or higher than a softening point and equal to or lower than a melting point of the thermoplastic elastomer
Implementation Method 2
a temperature equal to or higher than a softening point and equal to or lower than a melting point of the thermoplastic elastomer
Implementation Method 3
heating to be performed on the flexible circuit body... thereby the thermoplastic elastomer can be formed into a predetermined shape
Data Source
AI summary
Provided is a highly reliable flexible circuit body in which a flexible wiring board is prevented from wear caused by rubbing, and a method for production of the flexible circuit body. A flexible circuit body includes a flexible wiring board having an insulating film, a wiring layer formed on the insulating film, and an insulating layer formed on the wiring layer. The flexible wiring board is coated with a thermoplastic elastomer.