Flat Conductor Fastening via Ring Terminal and Aperture
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Solution Overview
Problem
Existing methods for connecting flat conductors, such as conductive copper tape and printed circuits, to traditional cylindrical wires in electrical assemblies are inefficient and prone to unintended electrical connections or shorting.
Innovation Solution
An electrical assembly is formed by creating an aperture in a substrate, mounting a flat conductor over it, connecting a round lead wire to a ring terminal adjacent to the aperture, and securing a fastener through the ring terminal and flat conductor, ensuring the ring terminal is secured against the flat conductor, thereby preventing shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional connection methods are used to connect flat conductors to cylindrical wires, then connection reliability may be maintained, but assembly complexity increases and space efficiency decreases
Solution Approach 1:
The patent combines the flat conductor, ring terminal, and fastener into a single integrated assembly that connects directly through the substrate aperture. This merging of components eliminates the need for separate connection steps and intermediate elements, reducing assembly complexity while maintaining connection reliability through the unified structural design.
Solution Approach 2:
The fastener serves multiple functions simultaneously: it secures the ring terminal to the flat conductor, maintains proper spacing from the substrate, and prevents unintended electrical connections. This multi-functionality reduces the number of components needed while ensuring reliable connection.
2Reliability
If multiple components are used to ensure secure connection and prevent shorting, then connection reliability improves, but device complexity and space requirements increase
Solution Approach 1:
The ring terminal integrates the connection interface and spacing function into a single component, while the fastener combines securing and insulation functions. This merging reduces the total number of components while maintaining reliability through the multifunctional design of each element.
Solution Approach 2:
Each component in the assembly performs multiple functions: the ring terminal provides both electrical connection and spacing, the fastener provides both mechanical securing and electrical insulation. This multi-functionality minimizes component count while ensuring reliable operation.
3Area of stationary object
If conventional connection methods are employed, then ease of manufacture may be maintained, but space efficiency and packaging improve with flat conductors
Solution Approach 1:
The connection is segmented into discrete functional elements (flat conductor, ring terminal, fastener) that can be manufactured separately using standard processes, then assembled in a simple sequence. This segmentation maintains manufacturing ease while achieving space efficiency through the compact flat conductor design.
Solution Approach 2:
The ring terminal is pre-positioned against the flat conductor before fastener installation, ensuring proper alignment and spacing is established beforehand. This preliminary action simplifies the final assembly step while maintaining the space-efficient compact design.
Data Source
AI summary
An electrical assembly that includes a substrate having an aperture. A flat conductor is mounted to the substrate and extends over at least a portion of the aperture, with a ring terminal in contact with the flat conductor adjacent to the aperture. A lead wire connects to the ring terminal and is spaced from the substrate, and a fastener extends through the ring terminal and flat conductor, secured in the aperture, and securing the ring terminal against the flat conductor.