Electrical Connector Biasing Surfaces for Printed Electrodes
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Solution Overview
Problem
Existing electrical connectors face challenges in reliably connecting non-resilient electrodes printed on substrates, such as flexible substrates, due to manufacturing complexity and wear issues, especially when repeatedly connected and disconnected.
Innovation Solution
An electrical connector system comprising a male and female connector with angled biasing surfaces and a rotational mechanism that clamps the electrode, providing a secure connection without relying on resilient contacts, and includes a substrate holder for interference fit to prevent buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sprung contacts are used to provide resilience and maintain electrical connection, then the reliability of electrical connection is improved, but the manufacturing complexity and cost increase, and the contacts become more prone to breaking
Solution Approach 1:
The patent removes the resilient support structure from the contact design, extracting the complexity of sprung contacts while maintaining connection reliability through a different mechanism. The contact is made simple by being directly printed onto the substrate without any resilient support, thereby reducing manufacturing complexity while solving the reliability issue through the connector's clamping action rather than contact resilience.
Solution Approach 2:
The patent embraces the disposable nature of printed contacts on flexible substrates by designing a connector system that accommodates non-resilient, inexpensive contacts. Instead of trying to make the contacts durable and resilient, the system is designed to work with simple printed contacts that can be easily replaced, reducing manufacturing cost and complexity while maintaining functional reliability through the connector's mechanical clamping action.
2Ease of manufacture
If contacts are printed using conductive ink to reduce manufacturing cost, then the manufacturing cost is reduced, but the contacts become prone to being worn off when repeatedly connected and disconnected
Solution Approach 1:
The patent applies preliminary action by providing a protective coating over the printed conductive ink contacts before they are subjected to repeated connection cycles. This coating is applied in advance to prevent the conductive ink from being worn off during use, thereby maintaining contact durability while preserving the low manufacturing cost advantage of printed contacts.
Solution Approach 2:
The patent uses composite materials by combining the printed conductive ink with a protective coating material. This composite structure maintains the electrical conductivity of the printed ink while adding the wear resistance of the coating material, thereby solving the durability issue without sacrificing the manufacturing cost advantage of printed contacts.
3Adaptability or versatility
If flexible substrates are used to enable disposable circuits, then the manufacturing cost is reduced and adaptability is improved, but the substrates become prone to buckling when inserted into a connector
Solution Approach 1:
The patent applies the nesting principle by providing a housing that encloses the flexible substrate and printed circuit board assembly. This housing protects the flexible substrate from buckling during insertion and use, while still allowing the substrate to maintain its flexibility for disposable circuit applications. The housing nests the flexible components in a stable configuration.
Solution Approach 2:
The patent solves the buckling problem by transitioning from a two-dimensional flexible substrate to a three-dimensional structured assembly within a housing. The housing provides structural support in the third dimension, preventing buckling while preserving the flexibility and disposable nature of the printed circuit board. This dimensional change stabilizes the flexible substrate without compromising its adaptability.
4Device complexity
If non-resilient printed contacts are used to simplify manufacturing, then the manufacturing complexity is reduced, but the electrical connection reliability deteriorates due to lack of resilience
Solution Approach 1:
The patent introduces an intermediary element - the resilient support structure or housing mechanism - that mediates between the simple non-resilient printed contact and the requirement for reliable electrical connection. This intermediary provides the necessary resilience and mechanical support to ensure consistent electrical connection while allowing the contact itself to remain simple and easy to manufacture through printing.
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
The system effectively connects flat, non-resilient electrodes printed on substrates with reduced wear and risk of buckling, offering a simple, cost-effective, and reliable method for both rigid and flexible substrates.
Implementation Method 1
the one or more biasing surfaces oppose a base of the female connector... the first electrode is urged towards the base of the female connector by the one or more biasing surfaces
Implementation Method 2
a rotational mechanism that clamps the electrode, providing a secure connection
Implementation Method 3
includes a substrate holder for interference fit to prevent buckling
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
An electrical connector system for providing an electrical connection between a first electrode and a second electrode printed onto a substrate. The system comprises a male connector comprising the first electrode located proximal to a first end of the male connector and a female connector comprising a coupling portion forming a cavity with an opening into which the first end of the male connector may be received, the coupling portion having one or more biasing surfaces that each oppose a base of the female connector. The electrical connector system is configured such that when the male connector is urged into the coupling portion, the first electrode is urged towards the base of the female connector by the one or more biasing surfaces to form an electrical connection between the first electrode and the second electrode positioned between the base and the first end of the male connector.