Conductive Sheet Fitting with Bent Apex and Water-Blocking Projection
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Solution Overview
Problem
The existing fitting-equipped conductive sheets face issues with variation in the sandwiched state and water ingress at the electrical connection points, particularly when exposed to wet environments, due to the displacement of lateral metal yarns and lack of effective water blocking mechanisms.
Innovation Solution
A conductive sheet with a conductive fitting featuring a bent apex and a projection with a smaller radius of curvature, where the ends of the conductive strands are pressed against the bent apex and sandwiched between it and another sandwiching portion, with the projection on the inner surface preventing water entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If lateral metal yarns are sandwiched by the pair of plate-shaped sandwiching portions, then the shape of the fitting-equipped conductive sheet is retained, but the lateral metal yarns are likely to be displaced longitudinally from the sandwiched position causing variation in the sandwiched state
Solution Approach 1:
The patent applies local quality by making only the longitudinal metal yarns protrude from the end of the sheet material while the lateral metal yarns are embedded within the end portion. This local differentiation allows the sandwiching portions to firmly grip the longitudinal yarns for consistent electrical connection without causing displacement of the lateral yarns, thus resolving the contradiction between shape retention and sandwiched state consistency.
2Manufacturing precision
If only the longitudinal metal yarns are sandwiched by the pair of plate-shaped sandwiching portions, then the occurrence of variation in the sandwiched state is reduced, but water is likely to travel along the longitudinal metal yarns to enter the electrical connection portion inside the connection fitting
Solution Approach 1:
The patent uses the lateral metal yarns as an intermediary protective element. By embedding the lateral yarns within the end portion while keeping longitudinal yarns protruding, the lateral yarns form a protective barrier that blocks water from traveling along the longitudinal yarns into the electrical connection portion, thus resolving the contradiction between sandwiched state consistency and water ingress prevention.
3Strength
If a firmly crimped portion is formed at the sandwiching portions to achieve large fixing strength, then the fixing strength is improved, but the complexity of the connection fitting structure increases
Solution Approach 1:
The patent merges the functions of shape retention, electrical connection, and water protection into a single integrated end portion structure. The longitudinal metal yarns provide both the protruding feature for sandwiching and the electrical connection path, while the embedded lateral yarns simultaneously retain the sheet shape and block water ingress, thus achieving large fixing strength without significantly increasing structural complexity.
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
This design reduces variation in the sandwiched state and effectively blocks water entry, ensuring reliable electrical connection and preventing rust or corrosion at the connection points.
Implementation Method 1
the ends of the plurality of conductive strands are electrically connected to the conductive fitting by being brought into pressure contact with the bent apex
Implementation Method 2
a projection having a smaller radius of curvature than the bent apex portion is formed on an inner surface of the first sandwiching portion or the second sandwiching portion at a position located on the conductive sheet material side relative to the bent apex so as to be in contact with the ends of the plurality of the conductive strands
Data Source
AI summary
A fitting-equipped conductive sheet including: a conductive sheet material in which a plurality of conductive strands are aligned planarly; and a plate-shaped conductive fitting attached to ends of the plurality of conductive strands, wherein the conductive fitting includes a folded-back portion, and a first sandwiching portion and a second sandwiching portion that are folded back with the folded-back portion as a starting point and the first sandwiching portion and the second sandwiching portion are opposed to each other.