Elastic Terminal Assembly for Bicycle Electrical Contact Reliability
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Solution Overview
Problem
The manufacturing costs of electrical devices in human-powered vehicles are high due to complex assembly processes and the need for multiple components, and there is a lack of efficient methods to maintain electrical contact and protect against static electricity.
Innovation Solution
The use of a deformable terminal member made of a non-metallic material to maintain elastic contact between conductive bodies, a rechargeable battery directly connected to the circuit board via solder, and a port cover with an integral electrical conductor to protect against static electricity, simplifying the structure and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal member is introduced to maintain electrical contact between the circuit board and additional device, then reliable electrical contact is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The terminal member integrates multiple functions into a single component: it provides electrical contact between the circuit board and additional device, maintains elastic pressure for reliable connection, and simplifies the assembly process. This merging of functions reduces the need for separate components while achieving reliable electrical contact.
Solution Approach 2:
The terminal member is designed with elastic properties that allow it to deform and maintain constant contact pressure. By changing the physical state from rigid to elastic, the terminal member automatically compensates for manufacturing tolerances and assembly variations, ensuring reliable electrical contact without complex adjustment mechanisms.
2Reliability
If multiple components are used to ensure electrical contact and static protection, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The terminal member serves multiple purposes simultaneously: it establishes electrical contact, maintains mechanical pressure, and contributes to static electricity protection when combined with the port cover. This multi-functionality reduces the total component count and manufacturing cost while meeting all functional requirements.
Solution Approach 2:
The port cover is designed as a composite structure with an insulating base material and an integrated conductive layer. This composite design provides both mechanical protection and static electricity protection functions in a single component, reducing the need for separate protective components and lowering manufacturing costs.
3Reliability
If a deformable terminal member is used to maintain elastic contact, then contact reliability is improved, but structural complexity increases
Solution Approach 1:
The terminal member transitions from a static rigid structure to a dynamic elastic structure that can deform and recover. This dynamic property allows the terminal member to automatically adapt to assembly variations and maintain constant contact pressure, improving contact reliability without requiring complex control systems.
Solution Approach 2:
The elastic terminal member self-regulates the contact pressure through its own deformation characteristics. When assembled, it naturally deforms to make contact and maintains constant pressure without requiring external adjustment mechanisms or control systems, simplifying the overall structure while ensuring reliable contact.
4Object-affected harmful factors
If the port cover is designed with an integral electrical conductor for static protection, then static electricity protection is achieved, but manufacturing complexity increases
Solution Approach 1:
The conductive layer is integrated directly into the port cover structure, merging the protective housing function with the static electricity protection function. This integration eliminates the need for separate protective components and simplifies the assembly process, reducing manufacturing complexity despite the added functional capability.
Solution Approach 2:
The port cover uses a composite structure combining an insulating base material with a conductive layer. This composite design is achieved through cost-effective manufacturing processes such as coating or lamination, providing static electricity protection without significantly increasing manufacturing complexity or cost.
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
This solution reduces manufacturing costs by simplifying assembly, maintaining reliable electrical contact, and effectively protecting against static electricity, while also improving the usability of the electrical device.
Implementation Method 1
The terminal member is deformable to elastically maintain contact between the first electrically conductive body and the second electrically conductive body in the attachment state
Data Source
AI summary
An electrical device of a human-powered vehicle comprises a circuit board and a terminal member. The circuit board includes a first electrically conductive body. The terminal member is configured to be at least partially provided between the circuit board and an additional device in an attachment state where the circuit board is attached to the additional device. The terminal member includes a second electrically conductive body configured to elastically maintain contact between the first electrically conductive body and the second electrically conductive body in the attachment state.