Flat Conductor Connection Apparatus Mechanical Load Isolation
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Solution Overview
Problem
Electrical systems with flat wire construction face weakening connections due to mechanical loads transmitted from data cables, which are larger and stiffer than the conducting elements, leading to instability in the electrical connection.
Innovation Solution
A connecting apparatus and method that includes a flat conductor member, an electrical connecting structure, an inflexible support structure, and connecting members to capture the flat conductor between the connecting and support structures, preventing mechanical load transmission by using a bolted interface and minimizing mechanical load transfer through the connecting pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a data cable is connected directly to a flat wire conductor, then electrical connection is established, but mechanical loads from the data cable are transmitted to the flat wire conductor, weakening the electrical connection
Solution Approach 1:
The connection system is divided into separate functional components: an electrical connecting structure for electrical connection, a support structure for mechanical support, and connecting members for assembly. This segmentation allows the electrical and mechanical functions to be decoupled, preventing mechanical loads from the data cable from being transmitted to the flat wire conductor while maintaining reliable electrical connection.
Solution Approach 2:
The support structure acts as an intermediary between the data cable and the flat wire conductor. It provides mechanical support and captures the flat wire conductor between the connecting structure and the support structure, thereby mediating the mechanical loads and preventing them from being transmitted to the delicate flat wire conductor.
2Reliability
If the flat wire conductor is captured between the connecting structure and the support structure, then mechanical load transmission is prevented, but the device complexity increases
Solution Approach 1:
Multiple functions are merged into integrated components. The electrical connecting structure incorporates both electrical connection features and mechanical capture features. The support structure provides both mechanical support and positioning functions. This merging reduces the number of separate components needed while maintaining the ability to prevent mechanical load transmission.
Solution Approach 2:
The connecting members serve multiple functions: they electrically connect the data cable to the flat wire conductor, mechanically capture the flat wire conductor between the connecting structure and support structure, and provide structural alignment. This multi-functionality reduces overall device complexity while achieving reliable connection and load isolation.
Data Source
AI summary
An apparatus for establishing a substantially unitary connecting structure including a generally flat conductor member carrying a first plurality of first electrical conductors and a second conductor member carrying a second plurality of second electrical conductors includes: (a) an electrical connecting structure configured for receiving the second conductor member to establish electrical connection between at least one first electrical conductor of the first plurality of first electrical conductors and at least one second electrical conductor of the second plurality of second electrical conductors; (b) a generally inflexible support structure; and (c) at least one connecting member traversing the flat conductor member and cooperating with the electrical connecting structure and the support structure for capturing the flat conductor member between the connecting structure and the support structure in an installed orientation.