Flat Circuit Connecting Structure with Protective Plate
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Solution Overview
Problem
Conductors in flat circuit bodies are damaged by crimp claws during connection, leading to decreased electrical performance under pulling loads, and the crimping process requires difficult force control to avoid excessive damage.
Innovation Solution
A connecting structure where crimp claws are crimped onto a protective plate overlaid on the conductor, ensuring surface contact without penetration, and the distal ends of the crimp claws press the protective plate in a folded form to maintain stability and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp claws penetrate through conductors to establish electrical connection, then electrical connection is achieved, but conductor damage occurs and electrical performance decreases under pulling loads
Solution Approach 1:
The patent introduces an insulating layer as an intermediary between the crimp claws and the conductor. The crimp claws penetrate through the insulating layer to contact the conductor, rather than directly penetrating the conductor itself. This intermediary layer prevents damage to the conductor structure while maintaining electrical connection, resolving the contradiction between achieving connection and preventing damage.
Solution Approach 2:
The insulating layer is pre-applied to the conductor surface before the crimping operation. This preliminary protective action ensures that when crimp claws are inserted, the conductor is already protected from direct mechanical damage, allowing reliable connection without subsequent damage expansion under pulling loads.
2Manufacturing precision
If crimp claws are shaped to curved form to control crimping pressure, then connection precision improves, but operativity decreases due to difficult force control
Solution Approach 1:
The insulating layer acts as a mediator that decouples the crimping force application from the conductor. The curved crimp claws press against the insulating layer rather than directly against the conductor, allowing easier force control during operation while the insulating layer transmits the necessary pressure to achieve precise connection.
Solution Approach 2:
The patent changes the physical parameters of the crimping interface by introducing the insulating layer with specific mechanical properties. This allows the crimping process to operate with more favorable force characteristics, improving operativity while maintaining connection precision through the controlled interaction between crimp claws and insulating layer.
Data Source
AI summary
A portion of a conductor of a flat circuit body is exposed from an insulating layer covering at least one of surfaces of the conductor. A terminal includes a bottom plate on which the exposed portion of the conductor is provided, and crimp claws which are raised at two side edges of the bottom plate so that the exposed portion of the conductor is disposed therebetween. A protective plate is provided on the exposed portion of the conductor, and has a strength so as not to be penetrated by the crimp claws when the crimp claws are crimped onto the protective member. The crimp claws are crimped onto the protective plate so that the terminal is crimped to the conductor in a state where the exposed portion of the conductor is in surface contact with the bottom plate.