Dual-Contact Connector for Flexible Substrate Surface Variations
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Solution Overview
Problem
Existing connectors are ineffective in establishing electrical connections with conductors exposed on the bottom surface of a flexible substrate.
Innovation Solution
A connector design featuring a plug contact with a tubular portion and flange, a bottom insulator with a support surface, and an inner contact with retaining and flat plate portions, allowing electrical connection regardless of conductor exposure on the top or bottom surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector is designed to connect to conductors exposed on the top surface only, then the connection structure is simple, but it cannot connect to conductors exposed on the bottom surface
Solution Approach 1:
The connector is designed with dual functionality: the plug contact can directly contact conductors on the top surface through the flange, while the inner contact can reach through the tubular portion to contact conductors on the bottom surface. This multi-functional design allows a single connector to handle both top-surface and bottom-surface conductor configurations, resolving the contradiction between versatility and complexity.
Solution Approach 2:
The inner contact is nested within the tubular portion of the plug contact. The tubular portion acts as a protective sheath that guides the inner contact to the bottom surface while allowing the flange of the plug contact to engage with top-surface conductors. This nested structure enables both contact types to coexist in a compact arrangement, achieving versatility without excessive complexity.
2Reliability
If the connector includes both direct contact and indirect contact paths, then it can connect to both top and bottom surface conductors, but the contact force distribution becomes complex
Solution Approach 1:
The contact mechanism is segmented into two independent contact paths: the plug contact's flange provides direct contact force for top-surface conductors, while the inner contact provides indirect contact force for bottom-surface conductors. Each segment operates independently with its own force application mechanism, simplifying the overall force distribution while maintaining reliable electrical connections for both conductor types.
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
Enables electrical connection to conductors on both top and bottom surfaces of a connection object, facilitating reliable data transmission in smart clothing applications.
Implementation Method 1
a flat plate portion being elastically deformable, joined to the retaining portion, extending in the direction perpendicular to the fitting axis
Data Source
AI summary
The connector includes a conductive plug contact, a bottom insulator, and a conductive inner contact, the inner contact including a retaining portion retained in a recessed portion of the plug contact, an elastically deformable flat plate portion facing a bottom surface of a flange of the plug contact, a plurality of top surface-side projections projecting toward the bottom surface of the flange from a top surface of the flat plate portion, and a plurality of bottom surface-side projections projecting toward a support surface of the bottom insulator from a bottom surface of the flat plate portion separately at positions different from positions of the top surface-side projections, part of a sheet type connection object having a conductor exposed on at least one surface thereof being sandwiched between the bottom surface of the flange of the plug contact and the top surface-side projections of the inner contact.