Flexible Circuit Wire Transition Member

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Solution Overview

Problem

Standardized wire termination connectors are limited in their ability to connect with flexible circuits, leading to weight and space issues due to the rigidity of wires, which restricts the use of flexible circuits in applications where reduced weight and compact routing are desired.

Innovation Solution

A transition member with a housing that includes recesses for flexible circuits and wires, along with contacts that provide an electrical connection between them, allowing for the integration of flexible circuits with standardized wire termination connectors, and the use of potting compound to secure the components in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wires are used to connect standardized wire termination connectors, then electrical connection is achieved, but weight increases and space requirements increase

Engineering Contradiction:

Improveelectrical connectionVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent changes the physical state and material properties by replacing rigid wire connections with a flexible circuit board that has a substrate and conductive traces. This parameter change from rigid to flexible construction reduces weight while maintaining electrical connectivity, directly resolving the contradiction between reliable electrical connection and weight reduction

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flexible circuit board employs composite materials consisting of a flexible substrate combined with conductive traces. This composite structure provides both the mechanical flexibility needed to reduce weight and the electrical conductivity required for reliable connection, simultaneously addressing both requirements of the contradiction

Inventive Principle:

Principle #40Composite materials

2Reliability

If wires are used to connect standardized wire termination connectors, then electrical connection is achieved, but space requirements increase due to difficulty in bending and conforming to small spaces

Engineering Contradiction:

Improveelectrical connectionVSAvoidspace

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent introduces dynamic flexibility by replacing static rigid wires with a flexible circuit board that can be dynamically bent and conform to various spatial configurations. This dynamic capability allows the electrical connection to adapt to small spaces and complex routing requirements, resolving the contradiction between reliable connection and space efficiency

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible circuit board functions as a flexible thin film structure that can be bent and conform to small spaces. This flexible construction maintains electrical connection reliability while dramatically reducing the space required for routing compared to rigid wires, directly addressing the space constraint in the contradiction

Inventive Principle:

Principle #30Flexible shells and thin films

3Weight of moving object

If flexible circuits are used to reduce weight and space, then weight and space requirements are reduced, but compatibility with standardized wire termination connectors is lost

Engineering Contradiction:

ImproveweightVSAvoidcompatibility

Core Design Contradiction:

Weight of moving objectVSAdaptability or versatility

Solution Approach 1:

The patent introduces an intermediary component - the flexible circuit board with contact pads - that mediates between the standardized wire termination connector and the flexible circuit requirements. This intermediary maintains compatibility with standard connectors while enabling the weight and space benefits of flexible circuits, resolving the contradiction between weight reduction and compatibility

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flexible circuit board design incorporates universal features including contact pads that can interface with standardized wire termination connectors. This multi-functional capability allows the flexible circuit to serve both as a lightweight, space-efficient connector and as a compatible interface for standard components, resolving the contradiction between weight reduction and adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9793631B1Flexible circuit to wire transition member and method

Publication Date: 2017.10.17 TYCO ELECTRONICS (UK) LTD

AI summary

A flexible circuit to wire transition member and method which transitions wires connected to a standard wire termination connector to a flexible circuit. The transition member includes a housing with a flexible circuit receiving recess provide proximate a first surface of the housing. A wire receiving recess is provided in the housing proximate a first surface of the housing. A contact extends between the flexible circuit receiving recess and the wire receiving recess, the contact provides an electrical connection between a flexible circuit received in the flexible circuit receiving recess and a wire received in the wire receiving recess.