Flexible Circuit Connector Assembly for Detachable Device Terminals
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Solution Overview
Problem
Conventional methods for connecting flexible circuits to electrical systems involve permanent connections via soldering or crimping, which are bulky and take up valuable space, and there is a need for detachable connections.
Innovation Solution
The use of electrical connectors with spring terminals and connection features such as clips, slots, and laser-processed FCs to create detachable and space-efficient connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional permanent connection methods (soldering, crimping) are used to connect flexible circuits to electrical systems, then reliable electrical connection is achieved, but the system becomes bulky and occupies valuable packaging space
Solution Approach 1:
The invention divides the connection system into separate modular components: a connector assembly that attaches to the flexible circuit and a corresponding receptacle on the electrical system. This segmentation allows the connection function to be separated from bulky permanent bonding structures, reducing overall packaging space while maintaining reliable electrical contact through standardized interfaces.
Solution Approach 2:
The connector and receptacle are designed to nest together, with the connector inserting into and being retained by the receptacle. This nesting arrangement allows the connection components to occupy minimal space when mated, eliminating the need for bulky external bonding structures while ensuring secure mechanical and electrical connection.
2Reliability
If conventional permanent connection methods (soldering, crimping) are used to connect flexible circuits to electrical systems, then stable electrical connection is achieved, but detachability and ease of replacement are lost
Solution Approach 1:
The invention transitions from static permanent connections to dynamic reversible connections. The connector and receptacle are designed with mechanical retention features (such as snap-fit elements, clips, or latches) that provide stable connection during operation but allow intentional detachment. This dynamic design enables easy replacement of flexible circuits while maintaining reliable electrical contact during use.
3Reliability
If conventional FC electrical connectors are designed for reliable connection, then connection stability is improved, but the connectors become bulky and increase weight
Solution Approach 1:
The invention employs thin-film flexible circuit technology for the connector components, replacing bulky rigid connector housings. The flexible circuit substrate serves as both the electrical conductor and the structural element, eliminating the need for heavy metal connector shells while maintaining connection stability through precise trace routing and flexible retention mechanisms.
Data Source
AI summary
An electrical system comprises a flexible circuit (FC) comprising at least one conductive circuit trace disposed within or between one or more dielectric layers and defining at least one exposed conductive circuit trace portion, an electrical device system comprising an electrical device disposed within a housing and at least one conductive terminal electrically connected to the electrical device and that extend substantially to an end of the housing, and an electrical connector configured to physically secure and electrically connect the at least one exposed conductive circuit trace portion to the at least one conductive terminal of the electrical device system, wherein the electrical connector and the housing of the electrical device system define at least one connection feature for physically securing to each other.