Flexible Conductive Connector with Pull-Tab Applicator for Compact Electronics
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Solution Overview
Problem
In compact electronic devices, existing connectors that use rigid materials for electrical connections often mechanically constrain components, limiting their mobility and requiring undesired design compromises to accommodate flexible printed circuits for mechanical freedom.
Innovation Solution
A thin sheet of flexible conductive material with an adhesive surface and a pull-tab release liner applicator allows for electrical connection between components while maintaining mechanical mobility, enabling the connector to be installed in a small gap between components using a pull-tab liner that can be easily removed after attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid electrical connecting material is used, then mechanical coupling strength is improved, but component mobility is reduced
Solution Approach 1:
The patent replaces rigid mechanical coupling with adhesive bonding using a pressure-sensitive adhesive layer on the flexible substrate. This substitution allows electrical connection without mechanical constraint, enabling component mobility while maintaining reliable electrical contact. The adhesive layer bonds the connector to component surfaces without restricting their relative movement.
Solution Approach 2:
The patent uses a flexible substrate (thin film) as the electrical connector instead of rigid material. This flexible substrate can bend and deform to accommodate component movement, providing both electrical connection and mechanical flexibility. The thin film nature allows it to conform to small gaps between components while maintaining electrical conductivity.
2Adaptability or versatility
If flexible printed circuit is used for component mobility, then component mobility is improved, but device space is increased
Solution Approach 1:
The patent employs an extremely thin flexible substrate (e.g., 0.002 to 0.010 inches thick) that provides the necessary flexibility for component mobility while occupying minimal space. This thin film approach achieves mobility without requiring the bulkier structure of traditional flexible printed circuits, thus preserving device compactness.
Solution Approach 2:
The connector is designed as a segmented structure with a flexible substrate and separate adhesive layer, allowing the adhesive to be applied only where needed for bonding. This segmentation enables precise placement in small gaps between components, reducing the overall space required while maintaining mobility functionality.
3Volume of moving object
If connector is installed in small gap between components, then device compactness is improved, but installation difficulty is increased
Solution Approach 1:
The adhesive layer is pre-applied to the flexible substrate before installation, and the connector is designed with the adhesive already in place. This preliminary preparation allows for quick installation by simply positioning the connector between components and applying pressure, eliminating the need for complex assembly procedures in tight spaces.
Solution Approach 2:
The pressure-sensitive adhesive layer acts as an intermediary that facilitates easy installation by providing immediate bonding upon contact. This adhesive mediator allows the connector to be securely attached in small gaps without requiring mechanical fasteners or complex alignment procedures, significantly easing the installation process.
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 solution enables efficient electrical connection without mechanical constraint, allowing components to move freely while maintaining reliable contact, thus enhancing the design flexibility and assembly efficiency of compact electronic devices.
Implementation Method 1
The thin sheet of flexible conductive material may include an adhesive surface and an opposing surface that is free of adhesive material. The adhesive surface may be attached to first and second electronic components to electrically connect the first electronic component to the second electronic component.
Implementation Method 2
The applicator may be a pull-tab release liner that is formed from one or more layers of a flexible material such as a flexible insulating material. The connector may be installed by inserting the connector and applicator between the first and second electronic components, pinching the first and second electronic components against the connector, and removing the applicator by pulling the extended portion to peel the applicator away from the connector.
Data Source
AI summary
Electronic devices may be provided with electronic components and electrical connectors coupled between the electronic components. A connector may be formed in a small gap between the electronic components. The connector may be a thin sheet of flexible conductive material with a conductive adhesive on one surface. The connector may be installed between the components using an applicator that is attached to the connector. The applicator may be a pull-tab liner having a first surface that is tacky and a second opposing surface that is non-stick. The applicator may have an extended portion that can be held by a technician while installing the connector. The connector may be installed by inserting the connector and applicator between the components, pinching the components against the connector and applicator, and removing the applicator by pulling the extended portion to peel the applicator from the connector.