Elastic Contact Terminal Structure for Metal Layer Crack Relief
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Solution Overview
Problem
Existing elastic electric contact terminals are prone to cracks and deformations in the metal layer due to concentrated stress when pressed vertically, especially when attached to circuit boards, and face challenges in defining spaces during manufacturing.
Innovation Solution
An elastic electric contact terminal design with a heat-resistant polymer film surrounding the core, adhesive layer, and a metal layer, featuring folded portions and defined spaces between the polymer film and core sidewalls to distribute stress and minimize deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the core is entirely attached to the polymer film, then structural integrity is improved, but stress concentration and crack formation occur in the metal layer when pressed
Solution Approach 1:
The patent divides the contact between the core and polymer film into segmented regions. The core is attached to the polymer film at the top and bottom surfaces but remains unattached at the side surfaces, creating distinct attached and unattached segments. This segmentation allows stress to be distributed differently across the structure, preventing stress concentration at the metal layer while maintaining overall structural integrity.
Solution Approach 2:
The patent applies different attachment qualities to different regions of the core. The top and bottom surfaces of the core have full attachment to the polymer film for structural support, while the side surfaces have no attachment to allow stress relief. This local differentiation of attachment quality enables the structure to simultaneously maintain integrity and resist cracking under compression.
2Reliability
If the non-conductive coating layer protrudes convexly to define a space, then stress distribution is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of making the coating layer protrude convexly to create space, the patent inverts the approach by creating a recessed portion in the core that receives the coating layer. This inversion simplifies the manufacturing process while still achieving the goal of defining a space for stress distribution. The recessed core design is easier to manufacture than a protruding coating design.
Solution Approach 2:
The patent uses the existing core geometry with recessed portions to define the space, rather than adding a separate protruding coating structure. The space is essentially a copy or negative space within the core structure itself, eliminating the need for complex protruding features and simplifying the overall manufacturing process.
3Stress or pressure
If the core expands laterally to fill the space, then stress relief is improved, but the metal layer becomes easily damaged
Solution Approach 1:
The patent pre-defines the space between the core and polymer film before compression occurs. The unattached side surfaces of the core create this space in advance, allowing the core to expand laterally in a controlled manner during compression. This preliminary space definition ensures that stress relief occurs without uncontrolled expansion that could damage the metal layer.
Solution Approach 2:
The space defined by the unattached core surfaces acts as a cushioning region before compression. When force is applied, the core can expand into this pre-defined space, absorbing and distributing stress gradually. This beforehand cushioning prevents sudden stress concentration that would otherwise damage the metal layer, while the polymer film constraints guide the expansion to protect the metal layer.
4Length of moving object
If the electric contact terminal has a short length, then mounting flexibility is improved, but soldering strength decreases
Solution Approach 1:
The patent uses composite material structures, particularly the combination of the core, polymer film, and metal layer. The polymer film provides structural support and stress distribution, while the metal layer provides soldering surfaces. This composite structure enables short terminal length while maintaining soldering strength through the distributed stress and reinforced construction.
Solution Approach 2:
The patent employs curved or bent configurations of the core, creating folded portions that provide mechanical strength. These curved sections act as reinforcement elements that maintain structural integrity and soldering strength even when the overall terminal length is short, as the curvature distributes stresses more effectively than straight configurations.
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 design minimizes cracks and deformations in the metal layer by distributing stress, enhances resilience, and improves soldering strength, even with short lengths, while maintaining structural integrity under external forces.
Implementation Method 1
a heat-resistant polymer film that continuously surrounds the core in a longitudinal direction and is attached to top and bottom surfaces of the core with an adhesive layer having elasticity therebetween
Implementation Method 2
an elastic core; an elastic electric contact terminal capable of minimizing generation of a crack of a metal layer even when the elastic electric contact terminal is pressed in a vertical direction by external force
Data Source
AI summary
Disclosed is an elastic electric contact terminal that does not give an effect on a metal layer even when a core is pressed by external force. The elastic electric contact terminal includes an elastic core, a heat-resistant polymer film that surrounds the core and is attached to top and bottom surfaces of the core with an adhesive layer therebetween, and a metal layer disposed on an outer surface of the polymer film. At least one sidewall of the core is pressed inward to form a folded portion, and a space is defined between an inner surface of the polymer film and the sidewall of the core by the folded portion.