Connector Structure for FPC Alignment and Wear Reduction
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Solution Overview
Problem
Conventional connector structures face defects in conduction when dealing with flexible printed circuits (FPCs) having plated leads, due to misalignment issues between the fork terminal and the plated lead, leading to runout and defects in electrical connection.
Innovation Solution
A circuit body with a two-pronged part and plated leads arranged on both sides of the two-pronged part, ensuring proper alignment and contact between the fork terminal and the plated leads, preventing misalignment and ensuring reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the line width of the plated lead is made thin to slow wear of cutting equipment, then the wear of cutting equipment is reduced, but the alignment precision between the fork terminal and plated lead deteriorates, causing runout and conduction defects
Solution Approach 1:
The plated lead structure is segmented into a wide base portion and a thin extended portion. The wide base portion (width equal to or greater than the fork terminal width) ensures proper alignment and prevents runout, while the thin extended portion continues from the center of the base to maintain slow wear characteristics during cutting operations.
Solution Approach 2:
Different portions of the plated lead have different width characteristics to serve different functions. The base portion has a wider width for alignment and stability, while the extended portion has a thinner width for reduced cutting equipment wear. This local differentiation resolves the contradiction between alignment precision and wear resistance.
2Manufacturing precision
If the line width of the plated lead is made wide to ensure proper alignment with the fork terminal, then the alignment precision is improved, but the wear of cutting equipment accelerates
Solution Approach 1:
The plated lead is divided into a wide base portion for alignment and a thin extended portion for cutting. This segmentation allows the system to benefit from both wide and narrow width characteristics in different regions, resolving the contradiction between alignment precision and cutting equipment wear.
Solution Approach 2:
The plated lead exhibits local quality variation where the base portion is wide for alignment purposes and the extended portion is thin for reduced wear. This spatial differentiation of properties allows simultaneous achievement of both alignment precision and wear resistance.
3Reliability
If strict alignment between the plated lead and fork terminal is enforced, then the conduction reliability is improved, but the manufacturing and assembly tolerance requirements become stricter
Solution Approach 1:
The wide base portion of the plated lead performs preliminary alignment action by providing a broad target area for the fork terminal. This preliminary alignment ensures that the fork terminal is properly positioned before the thinner extended portion makes the final electrical connection, thereby improving conduction reliability while maintaining reasonable tolerance requirements.
Data Source
AI summary
A connector structure includes a circuit body, a fork terminal, a housing and an insertion member. The circuit body includes a conductor including a two-pronged part having two extended portions, and plated leads arranged at the extended portions respectively. The fork terminal includes a first terminal part and a second terminal part which project from a terminal base so that an insertion space is formed between the first and second terminal parts. The housing includes a fitting part accommodating the fork terminal. The insertion member is inserted into the insertion space through the fitting part in a state where the circuit body is fixed. The circuit body is electrically connected with one of the first and second terminal parts with the insertion of the insertion member.