Flexible Substrate Connector Assembly With Protective Sheet Waterproofing
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Solution Overview
Problem
Existing connector assemblies for flexible substrates face disconnection issues when adhesive agents are heated, leading to impaired functionality and potential water intrusion due to the dissolution of the resin film forming the flexible conductor.
Innovation Solution
A connector assembly featuring a housing with a pressure-sensitive adhesive layer on an insulating film, which covers the flexible substrate and is adhered to the housing, preventing direct contact between the adhesive and the flexible conductor, thus maintaining structural integrity and electrical connection while providing waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If additional waterproof members are added to prevent water penetration, then waterproofing is improved, but the device complexity increases
Solution Approach 1:
The protective sheet is designed to serve multiple functions simultaneously: it protects the flexible conductor from heat and adhesive during the bonding process, and also provides waterproofing by preventing water from penetrating between the connector and the flexible substrate. This multi-functionality eliminates the need for separate waterproof members, reducing device complexity while maintaining improved waterproofing
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
The solution effectively prevents deformation and disconnection of flexible conductors during heating treatments, ensuring reliable electrical connections and waterproof properties without the need for additional waterproof members.
Implementation Method 1
a pressure-sensitive adhesive layer formed on one surface of the protection sheet and disposed between the housing and the flexible substrate such that the pressure-sensitive adhesive layer faces the flexible substrate
Implementation Method 2
An adhesive agent made of a thermosetting resin undergoes a chemical reaction caused by being heated and is cured, whereas an adhesive agent made of a thermoplastic resin is softened by being heated and is then cured by being cooled
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A connector includes a contact connected to a flexible conductor, a housing that is attached to a flexible substrate and retains the contact, and a protection sheet that is constituted of an insulating film having a pressure-sensitive adhesive layer formed on one surface thereof and is disposed between the housing and the flexible substrate such that the pressure-sensitive adhesive layer faces the flexible substrate, the protection sheet being disposed so as to cover at least a front surface part of the flexible substrate on which the flexible conductor is formed, and is adhered to the flexible substrate with the pressure-sensitive adhesive layer, the housing having a flat surface facing the flexible substrate, an adhesive layer bonding the housing to the protection sheet being disposed between the flat surface and the protection sheet.