Flexible Circuit Connection With Clip-Locked Detachable Terminals
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Solution Overview
Problem
Conventional methods for connecting flexible circuits to electrical systems are often permanent, bulky, and occupy valuable space, lacking a detachable and efficient solution for component replacement.
Innovation Solution
The development of an electrical system with a flexible circuit and an electrical connector that includes exposed conductive circuit traces, secured by spring terminals and connection features such as clips or slots, allowing for removable and secure connections, and processed using laser techniques to define connection features and expose conductive traces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional permanent connection methods (soldering, crimping) are used to connect flexible circuits to electrical systems, then reliable electrical connection is achieved, but the connection cannot be detached for component replacement and the system becomes bulky
Solution Approach 1:
The patent divides the electrical connection system into separable segments: a connector portion attached to the flexible circuit and a corresponding receptacle portion attached to the electrical system. This segmentation allows the connection to be reliable when mated while enabling detachment for replacement, directly resolving the contradiction between connection reliability and ease of operation for component replacement.
Solution Approach 2:
The patent implements a dynamic connection system that transitions between connected and disconnected states. The connector and receptacle are designed to engage firmly for reliable electrical connection but can be easily disengaged for component replacement, providing the flexibility needed to resolve the contradiction between permanent connection reliability and detachability.
2Reliability
If conventional electrical connectors are used to connect flexible circuits, then electrical connection is achieved, but the connectors are bulky and occupy valuable packaging space
Solution Approach 1:
The patent extracts the essential connection functionality from bulky conventional connectors, implementing a streamlined connector design that maintains reliable electrical connection while minimizing volume. The connector portion is designed to attach directly to the flexible circuit trace without requiring large housing structures, thereby reducing packaging space occupation while preserving connection reliability.
Solution Approach 2:
The patent utilizes thin-film and flexible construction techniques for the connector and receptacle components. The connector is designed as a thin, flexible element that can be attached directly to the flexible circuit trace, eliminating the need for bulky rigid housings and significantly reducing the volume occupied in the packaging space while maintaining reliable electrical connection.
3Stability of the object's composition
If conventional permanent connection methods are used, then stable electrical connection is achieved, but component damage can occur and replacement is difficult
Solution Approach 1:
The patent segments the electrical connection into a removable connector portion and a receptacle portion, allowing the flexible circuit with its connector to be easily replaced as a modular unit. This segmentation maintains stable electrical connection during operation while enabling simple component replacement when damage occurs, directly resolving the contradiction between connection stability and ease of repair.
Solution Approach 2:
The patent implements a dynamic connection system that provides stable electrical connection during normal operation through firm engagement of the connector and receptacle, while allowing easy disengagement for component replacement. This dynamic capability resolves the contradiction by providing both connection stability and ease of repair at different operational stages.
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
Enables a detachable, efficient, and space-saving electrical connection that can be manually or robotically installed, reducing component damage and packaging issues while ensuring reliable contact and insulation.
Implementation Method 1
processed using laser techniques to define connection features and expose conductive traces
Data Source
AI summary
An electrical system comprises a flexible circuit (FC) comprising at least one conductive circuit trace disposed within or between one or more dielectric layers and defining at least one exposed conductive circuit trace portion, an electrical device system comprising an electrical device disposed within a housing and at least one conductive terminal electrically connected to the electrical device and that extend substantially to an end of the housing, and an electrical connector configured to physically secure and electrically connect the at least one exposed conductive circuit trace portion to the at least one conductive terminal of the electrical device system, wherein the electrical connector and the housing of the electrical device system define at least one connection feature for physically securing to each other.