Flat Circuit Terminal Connection Using Spacer Member
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Solution Overview
Problem
Conventional connecting methods for flat circuit bodies and terminals often damage flat conductors due to crimping, leading to decreased electrical connection performance under pulling loads and require difficult force control during crimping operations.
Innovation Solution
A connecting structure that uses a spacer member with crimp claws to crimp onto, ensuring surface contact with the terminal's bottom plate without penetrating the conductor, thereby preventing damage and simplifying the crimping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp claws penetrate through the flat conductor to achieve electrical connection, then electrical connection is established, but the flat conductor is damaged and connection performance decreases under pulling loads
Solution Approach 1:
The patent introduces an insulating layer as an intermediary between the crimp claw and the flat conductor. The crimp claw crimps the flat conductor while the insulating layer prevents direct contact and damage to the conductor, allowing electrical connection through the insulating layer without compromising conductor integrity
Solution Approach 2:
The insulating layer serves as a protective cushion that is applied beforehand to the flat conductor. This cushioning layer absorbs and distributes the crimping force, preventing direct damage to the conductor while still allowing electrical connection to be established
2Reliability
If crimp claws are pressed with high force to ensure contact, then electrical connection is secured, but precise force control becomes difficult and operation complexity increases
Solution Approach 1:
The insulating layer acts as a mediator that decouples the force application from the conductor. The crimp claw applies force to the insulating layer rather than directly to the conductor, making force control easier while still ensuring reliable electrical connection through the insulating layer
Solution Approach 2:
The patent changes the material parameter of the insulating layer to have appropriate hardness and elasticity. This allows the insulating layer to be compressed under crimping force while maintaining its integrity, providing a consistent and predictable crimping process without requiring precise force control
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 method stabilizes electrical connection performance by preventing conductor damage from pulling loads and eliminates the need for precise force control during crimping, ensuring reliable connections.
Implementation Method 1
the spacer member is plastically deformed so as to contact with inner surfaces of the crimp claws when the crimp claws are crimped onto the spacer member
Data Source
AI summary
A portion of a flat conductor of a flat circuit board is exposed from an insulating layer covering at least one of surfaces of the flat conductor. A terminal includes a bottom plate on which the exposed portion of the flat conductor is provided, and crimp claws which are raised at two side edges of the bottom plate so that the exposed portion of the flat conductor is disposed therebetween. A spacer member is provided on the exposed portion of the flat conductor, and is configured to be plastically deformed so as to contact with inner surfaces of the crimp claws when the crimp claws are crimped onto the spacer member, thereby the terminal is crimped to the flat conductor in a state where the exposed portion of the flat conductor is in surface contact with the bottom plate.