Electrical Connector With Alternating Conductor Thickness
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Solution Overview
Problem
Conventional electrical connectors are not adequately suited for high mechanical loads, particularly when connecting components with non-planar terminals, leading to conductor breakage and compromised electrical properties due to excessive bending within the insulation zone.
Innovation Solution
An electrical connector design featuring flat conductors with alternating sections of different thicknesses, allowing for easier bending within the insulation zone while distributing stress across multiple areas, preventing buckling and maintaining electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional electrical connectors with uniform thickness conductors are used, then structural strength is maintained, but the connectors cannot withstand high bending stresses and conductors break or crack
Solution Approach 1:
The patent applies local quality by creating alternating thick and thin sections along the conductor length. The thin sections (first sections) are positioned at specific locations within the insulation zone to facilitate bending, while the thick sections (second sections) maintain structural strength. This non-uniform thickness distribution allows the conductor to bend without breaking at critical locations while maintaining overall structural integrity.
Solution Approach 2:
The conductor is segmented into multiple first sections (thin) and second sections (thick) along its length. This segmentation allows different portions of the conductor to serve different functions: thin sections for flexibility and bending, thick sections for strength and electrical connection. The segmented structure prevents stress concentration that would occur in uniform thickness conductors.
2Adaptability or versatility
If the conductors are made thinner to allow bending, then flexibility improves, but the conductors lack mechanical resistance and electrical properties
Solution Approach 1:
The conductor structure implements local quality by varying thickness along its length. Thin first sections provide the necessary flexibility and adaptability for bending in confined spaces, while thick second sections restore mechanical resistance and maintain electrical properties. This localized variation in thickness allows the conductor to exhibit both flexibility and strength in different regions.
Solution Approach 2:
The conductor is divided into alternating thin and thick segments. The thin segments (first sections) provide bending flexibility where needed, while the thick segments (second sections) provide mechanical strength and electrical conductivity. This segmented approach allows the overall conductor to achieve both flexibility and structural integrity.
3Manufacturing precision
If electrical connectors are customized for specific spatial arrangements, then connection accuracy improves, but manufacturing complexity and variety increase
Solution Approach 1:
The patent applies universality by designing a single connector type with alternating thick and thin conductor sections that can adapt to various spatial arrangements and bending requirements. This standardized design with inherent flexibility eliminates the need for multiple specialized connector variants, reducing manufacturing complexity while maintaining the ability to accommodate different component configurations.
Data Source
Figure 1a~1c
Figure 2
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AI summary
The invention relates to an electrical connector, particularly suitable for connecting printed circuit boards, wherein the connector (1) comprises several spaced-apart flat conductors (2) embedded in an electrically insulating material, forming an insulating zone (3) in which the flat conductors (2) run parallel to each other and each projecting at its end with an exposed section (5) beyond the transverse edges (4) of the insulating zone (3). It is provided that each flat conductor (2) within the insulating zone (3) has at least one first section (6) arranged between two second sections (7), the first section (6) having a smaller thickness than the second sections (7).