Dual-Surface Connector Contact for Flexible Conductor Alignment
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Solution Overview
Problem
Existing connectors fail to establish an electrical connection with flexible conductors when they are exposed on the top surface of a connection object, as they are designed to contact conductors only on the bottom surface.
Innovation Solution
A connector design that includes a first insulator, an inner insulator, and a second insulator, with contacts projecting perpendicularly to the connection object, allowing electrical connection regardless of the conductor's surface exposure through a mechanism where the connection object is sandwiched between the insulators' surfaces, ensuring contact on both surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the contact is designed to contact the flexible conductor only on the bottom surface, then the connector structure is simple, but the connector cannot establish electrical connection when the flexible conductor is exposed on the top surface
Solution Approach 1:
The contact is designed with two connection portions extending in opposite directions perpendicular to the longitudinal direction, enabling electrical connection in both vertical dimensions (top and bottom surfaces). This dimensional extension allows the contact to adapt to different conductor exposure positions without increasing overall structural complexity
Solution Approach 2:
The contact structure serves multiple functions: it can establish electrical connection with conductors exposed on either the top or bottom surface of the connection object. The first and second connection portions enable the same contact to universally interface with conductors regardless of their exposure position, eliminating the need for separate contact designs
2Reliability
If the connection object is sandwiched between insulators, then electrical connection reliability is improved, but the risk of conductor scratching increases
Solution Approach 1:
The insulators are designed with localized recessed portions that precisely accommodate the connection object. These recessed portions create a protected local environment where the connection object is sandwiched securely without exposing sharp edges or protrusions that could scratch the flexible conductor, thus maintaining both reliability and preventing damage
3Area of stationary object
If the contact projects perpendicularly to the connection object, then the contact area is increased, but the contact becomes more susceptible to mechanical stress
Solution Approach 1:
The contact is segmented into distinct portions: a longitudinal portion for structural support and first/second connection portions for electrical connection. This segmentation allows the longitudinal portion to bear mechanical stress while the connection portions maintain optimal contact area with the conductor, distributing mechanical loads away from the critical contact interfaces
Data Source
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AI summary
In a connector, a contact includes: a first connection portion and a second connection portion that are retained between a first insulator and a second insulator and face each other; and a pressing force receiving portion that makes contact with the second insulator and receives a pressing force from the second insulator to thereby press the first connection portion against the second connection portion. A connection object is sandwiched between the first connection portion and the second connection portion, and at least one of the first connection portion and the second connection portion makes contact with a flexible conductor of the connection object, whereby the contact is electrically connected to the flexible conductor of the connection object.