Elastic Contact Terminal Structure for Angled Electrical Pathways
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric contact terminals struggle to provide electrical pathways between objects disposed at different angles, are difficult to mount and fix to non-solderable surfaces, and have issues with mechanical strength and corrosion resistance.
Innovation Solution
An elastic electric contact terminal with a core surrounded by a metal foil and adhesive, featuring a corrosion-preventing layer and a terminal part that can be bent and welded/soldered for versatile electrical connections, and includes a polymer support for enhanced stability and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polymer film is used to cover the core, then mechanical strength and electrical insulation are improved, but electrical conductivity and ease of mounting to non-solderable surfaces deteriorate
Solution Approach 1:
The terminal is divided into two distinct parts: a polymer film-covered portion for mechanical strength and insulation, and a metal layer portion for electrical conductivity and versatile mounting. This segmentation allows each part to fulfill its specific function without compromise
Solution Approach 2:
Different regions of the terminal have different material properties: the polymer film region provides mechanical protection and insulation where needed, while the metal layer region provides conductivity and mounting capability at the terminal end, creating local quality variation to resolve the contradiction
2Reliability
If metal layers are formed in the vertical direction, then electrical pathways between vertically disposed objects are improved, but adaptability to objects at different angles and mounting versatility deteriorate
Solution Approach 1:
The terminal structure is made flexible and adaptable through the combination of elastic core and metal layer configuration, allowing it to bend and conform to objects at various angles while maintaining reliable electrical contact, transforming from a rigid vertical-only structure to a dynamic multi-directional structure
3Ease of manufacture
If the core is made of foam with low mechanical strength, then ease of manufacture and elasticity are improved, but structural integrity and resistance to external force deteriorate
Solution Approach 1:
The terminal combines foam core material with low mechanical strength but good elasticity and manufacturability, with a metal layer having high mechanical strength and conductivity. This composite structure allows the foam to provide ease of manufacture and elasticity while the metal layer compensates for the structural integrity deficiency
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
The terminal provides reliable electrical connections in various orientations, is easily mountable, and offers improved mechanical strength and corrosion resistance, ensuring stable electrical pathways and reduced deformation.
Implementation Method 1
a metal foil bonded to top and bottom surfaces of the core with an elastic adhesive therebetween
Implementation Method 2
a corrosion preventing layer formed on one surface of the metal foil
Data Source
AI summary
Disclosed is an elastic electric contact terminal capable of implementing various electrical pathways. The electric contact terminal includes: an elastic core; a polymer film surrounding the core in a width direction thereof; and a conductive laminate in which a metal foil is laminated on an outer surface of the polymer film. The polymer film is bonded to top and bottom surfaces of the core with an adhesive layer therebetween, and one end of the conductive laminate extends lengthily to the outside of the core to form a terminal part.