Circuit Element Connection Structure With Through-Base Connector

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for connecting circuit elements to connection terminals face issues such as wiring defects, poor workability, and complex mold structures due to the need for precise positioning and additional components, especially when using fine wires or heating elements.

Innovation Solution

A circuit element connection structure featuring a plate-shaped base with an opening, a conductive circuit element overlapping the opening, a conductive connector overlapping the opening, and a fixing member holding the circuit element between the connector and the base, allowing easy electrical connection and reducing the need for complex molds and additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If connection terminals are fixed to resin sheet before disposing metal wire, then connection terminals can be securely positioned, but wiring defects occur during metal wire disposal due to terminals being obstacles

Engineering Contradiction:

Improveconnection terminal positioningVSAvoidwiring defect rate

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The connection terminal is divided into two separate components: a terminal body fixed to the resin sheet and a connection portion that protrudes through the resin sheet. This segmentation allows the metal wire to be disposed first, then the terminal body is fixed around the wire, eliminating the obstacle problem while maintaining secure positioning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conventional sequence is inverted: instead of fixing terminals first then disposing wires, the metal wire is disposed on the resin sheet first, and then the terminal body is fixed to the resin sheet while surrounding the wire. This reversal eliminates wiring defects caused by terminals being obstacles.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If metal wire is twined around connection terminals, then electrical connection is achieved, but dedicated jigs are required resulting in poor workability and wire breakage risk

Engineering Contradiction:

Improveelectrical connectionVSAvoidworkability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The complex twining operation is extracted and replaced by a simpler process: the terminal body is fixed to the resin sheet in a crimped manner that automatically secures the wire. This eliminates the need for dedicated jigs and reduces wire breakage risk while maintaining reliable electrical connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The terminal body structure itself provides the securing function through its crimped fixation to the resin sheet, eliminating the need for external jigs or complex twining operations. The system serves itself by integrating the securing mechanism into the terminal body design.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If metal wire is disposed over terminals for connection, then connection is simplified, but lifted portion of metal wire remains broken after crimped portions are welded

Engineering Contradiction:

Improveconnection simplicityVSAvoidwire integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The terminal is segmented into a terminal body that is crimped to the resin sheet and a connection portion that extends through the sheet. This segmentation ensures that the wire is securely held in the crimped portion while the connection portion provides a reliable welding surface, eliminating the lifted portion problem.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal body is preliminarily fixed to the resin sheet in a crimped manner before the welding process. This preliminary fixation secures the wire in place, preventing any lifted portions from breaking during subsequent welding operations.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If connector is positioned at end of resin film for heating wire connection, then heating wire can be drawn out, but connector position is limited and workability deteriorates for extra-fine wires

Engineering Contradiction:

Improveheating wire extractionVSAvoidconnector position flexibility

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The connector design with a base fixed to the resin sheet and a connection portion protruding through it provides universal applicability. The connector can be positioned at any location on the resin sheet, not just at the end, and can handle various wire types including extra-fine wires, heating wires, and signal wires, improving versatility and workability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4184720B1Circuit element connection structure and circuit element connection structure unit

Publication Date: 2025.12.17 HOSIDEN CORP

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

A circuit element connection structure includes: a plate-shaped base (1) made of an insulating material and having an opening (1a) through the entire base in a thickness direction thereof; a circuit element (2) made of an electrically conductive material and disposed on a first side of the base (1) in the thickness direction thereof; and a connector (3) made of an electrically conductive material and disposed on a second side of the base (1) in the thickness direction thereof, the circuit element (2) and the connector (3) being in contact with each other at the opening (1a) as viewed in the thickness direction of the base (1).