Vehicle Connector Assembly With Direct Terminal-to-Substrate Contact
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Solution Overview
Problem
Existing connector devices with multiple contact points between flat circuit bodies and electric wires are prone to increased resistance due to oxidation, wear, or foreign matter, which degrades electrical performance.
Innovation Solution
A wire connector device with a first connector attached to a flat circuit body and a second connector that holds a terminal, allowing direct contact between the terminal and the flat circuit body, thereby reducing the number of contact points to two.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple contact points are used to connect flat circuit body and electric wire, then connection reliability is improved, but electrical performance deteriorates due to increased resistance from oxidation, wear, and foreign matter
Solution Approach 1:
The invention extracts and eliminates the intermediate female terminal from the connection path. By allowing the male terminal to directly contact the flat circuit body, the patent removes one contact point (the female terminal) from the system, thereby reducing the number of interfaces where oxidation, wear, and foreign matter can accumulate, ultimately lowering electrical resistance while maintaining connection reliability.
Solution Approach 2:
The invention merges the functions of the female terminal and male terminal into a single direct contact interface. Instead of having separate male and female terminals that mate with each other, the design allows the male terminal to directly engage with the flat circuit body, combining what were previously two separate connection interfaces into one, thereby reducing the total number of contact points.
2Reliability
If multiple terminals and contact points are used, then connection stability is improved, but device complexity increases
Solution Approach 1:
The invention extracts the female terminal component from the assembly, eliminating it entirely. This removal simplifies the device structure by reducing the number of components that need to be manufactured, assembled, and maintained, while the direct contact between the male terminal and flat circuit body maintains connection stability.
Solution Approach 2:
The invention merges multiple components (female terminal, male terminal, and their mating interfaces) into a simplified single-contact configuration. By combining these elements into a direct male-terminal-to-circuit-body connection, the patent reduces device complexity while preserving the essential function of electrical connection.
3Reliability
If three contact points are used for connection, then electrical connection is achieved, but manufacturing cost increases due to additional components
Solution Approach 1:
The invention extracts and eliminates the female terminal component from the design. This removal reduces the bill of materials and assembly steps required for manufacturing, directly lowering production costs while maintaining adequate electrical connection through the simplified direct-contact configuration.
Solution Approach 2:
The invention merges the connection function into a single interface rather than requiring three separate contact points. This consolidation reduces the number of components that need to be manufactured and assembled, thereby reducing manufacturing complexity and cost while achieving the same electrical connection objective.
Data Source
AI summary
A connector device is a device used by being mounted on a vehicle to connect a flexible substrate and an electric wire. The connector device includes a first connector attached to the flexible substrate, a terminal attached to the electric wire, and a second connector (3) that holds the terminal, configured to be connectable to the first connector, and connected to the first connector to bring the terminal into direct contact with a wiring portion of the flexible substrate and connect the terminal to the wiring portion.