Integrated Connector Assembly for Compact Flexible Wire Joining
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Solution Overview
Problem
Conventional connectors for connecting electric wires to flexible conductive members in smart clothing result in higher electric resistance and larger device sizes, with separatable connections impairing reliability.
Innovation Solution
A connector assembly comprising a first and second insulator with specific retaining surfaces, recesses, and protrusions that securely hold a flexible conductor and electric wire together, reducing size and enhancing reliability by ensuring a stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is designed to connect an electric wire to a flexible conductor of a sheet type conductive member, then the electrical connection reliability is improved, but the device size increases
Solution Approach 1:
The patent merges the first connector and second connector into a single integrated connector structure. The first insulator and second insulator are joined together to form one unified component that simultaneously provides both connection functions, eliminating the need for separate connectors while maintaining reliable electrical connection between the electric wire and flexible conductor
Solution Approach 2:
The patent employs a nested structure where the projection from the first insulator is inserted into the recessed portion of the second insulator, and the flexible conductor is nested within the opening portion of the sheet type conductive member. This nested arrangement allows multiple functional elements to be compactly integrated, reducing overall connector size while ensuring stable electrical connection
2Adaptability or versatility
If two separate connectors are used to connect electric wires to flexible conductors, then the connection flexibility is improved, but the device size increases and connection reliability decreases
Solution Approach 1:
The patent combines the functions of two separate connectors into one integrated connector assembly. The first insulator and second insulator work together as a unified structure, providing both the connection to the electric wire and the connection to the flexible conductor within a single component, thereby reducing device size while maintaining connection flexibility
Solution Approach 2:
The integrated connector design provides multi-functionality by simultaneously achieving: (1) mechanical connection between electric wire and flexible conductor, (2) electrical connection through the conductor portion, (3) insulation through the insulator bodies, and (4) structural support through the joined insulators. This universal design eliminates the need for multiple separate connectors
3Ease of manufacture
If a separatable connection is used between connectors, then the ease of assembly is improved, but the electrical connection reliability deteriorates
Solution Approach 1:
The patent merges the first connector and second connector into a single integrated assembly where the insulators are joined together. This eliminates the separatable connection between two distinct connectors, thereby ensuring continuous and reliable electrical connection while still allowing for straightforward assembly of the overall connector assembly
Data Source
AI summary
A connector includes a first insulator having a recessed portion formed in a first retaining surface and a projection formed in the recessed portion to project higher than the first retaining surface, and a second insulator having a protrusion portion formed on a second retaining surface and a projection accommodating portion of recess shape formed in the protrusion portion and is deeper than the second retaining surface, the first insulator and the second insulator being joined to each other such that the projection is inserted in an opening portion of a sheet type conductive member, that the sheet type conductive member and an electric wire are held between the first retaining surface and the second retaining surface, and that the sheet type conductive member and the electric wire are disposed to overlap each other between the recessed portion and the protrusion portion.