Connector Projections with Gaps for Flexible Conductors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors face difficulties in smoothly connecting to flexible conductors with insufficient stretchability, leading to redundant portions and impaired electric connection reliability due to inadequate contact pressure.
Innovation Solution
A connector design featuring a base member with projections that have gap forming portions to accommodate redundant portions, ensuring reliable electrical contact by allowing projections to be inserted smoothly and applying consistent pressure on flexible conductors, even when they lack stretchability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the diameter of the projection is reduced to prevent redundant portions from being caught, then the ease of operation is improved, but the contact pressure becomes insufficient and reliability deteriorates
Solution Approach 1:
The projection is segmented into multiple protruding portions (first, second, third protruding portions) arranged circumferentially. This segmentation allows each portion to independently press different regions of the flexible conductor, distributing the contact pressure and preventing redundant portions from being caught while maintaining sufficient overall contact pressure for reliable electrical connection.
Solution Approach 2:
Different regions of the projection have different functional qualities: the protruding portions are designed to contact and press the flexible conductor at specific locations, while the gap forming portions create controlled spaces to accommodate redundant portions. This local differentiation allows the projection to simultaneously prevent catching and maintain contact pressure.
2Reliability
If the projection diameter is maintained large to ensure contact pressure, then the reliability of electric connection is improved, but redundant portions are caught and ease of operation deteriorates
Solution Approach 1:
By segmenting the projection into multiple protruding portions with gap forming portions between them, the structure maintains an overall large diameter for sufficient contact pressure while creating localized gaps that prevent redundant portions from being caught during insertion.
Solution Approach 2:
The gap forming portions act as intermediary spaces that mediate between the flexible conductor and the projection. These gaps allow redundant portions to pass through or be accommodated during insertion, preventing the catching issue while the protruding portions maintain the necessary contact pressure for reliable electrical connection.
3Manufacturing precision
If the projection is designed as a solid cylindrical column, then the manufacturing precision is improved, but the flexibility adaptation worsens due to redundant portions being caught
Solution Approach 1:
The projection is segmented into protruding portions and gap forming portions, creating a structured pattern that can be precisely manufactured while adapting to flexible conductors with varying stretchability. The segmented design allows the projection to work with both highly stretchable and non-stretchable flexible conductors by accommodating redundant portions in the gaps.
Solution Approach 2:
The projection design changes the geometric parameters by introducing gap forming portions between protruding portions. This parameter change allows the structure to adapt to different flexible conductor properties (stretchability) while maintaining manufacturing precision through the defined geometric pattern of protrusions and gaps.
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
A connector includes a pushing member (14, 61) having a projection (15, 31, 41, 51), and a contact (13) made of a conductive material and having a projection accommodating portion (13D) of recess shape into which the projection is to be inserted, the projection (15, 31, 41, 51) having a protruding portion (15A, 31A, 41A) that is situated in a lateral surface of the projection with protruding from the lateral surface of the projection and approaches an inner surface of the projection accommodating portion when the projection is inserted into the projection accommodating portion, and a gap forming portion (15B, 31B, 41B) that is situated in the lateral surface of the projection around the protruding portion and forms a predetermined gap (G2) between the gap forming portion and the inner surface of the projection accommodating portion when the projection is inserted into the projection accommodating portion, the predetermined gap (G2) being wider than a distance (G1) between the protruding portion and the inner surface of the projection accommodating portion.