Flexible Jacket Flex Connector for Modular Power Distribution
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Solution Overview
Problem
Existing flex connectors in modular power distribution systems have rigid plastic covers that resist bending and twisting, making installation challenging and exposing conductors, which is undesirable.
Innovation Solution
A flexible jacket made from thin plastic sheets encloses the conductors, allowing for bending and twisting while maintaining a thin profile, and an improved manufacturing process secures the jacket layers together using heat sealing or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid plastic cover is used to enclose conductors, then structural strength and conductor protection are improved, but flexibility for bending and twisting deteriorates
Solution Approach 1:
The patent replaces the rigid plastic cover with a flexible jacket made from thin plastic sheets that completely encloses the conductors. This flexible jacket allows the flex connector to be bent and twisted during installation while still providing complete enclosure and protection of the conductors, thereby resolving the contradiction between structural strength and flexibility.
2Ease of operation
If transverse slots are added to the plastic cover to facilitate flexing, then ease of installation is improved, but conductor exposure and safety deteriorate
Solution Approach 1:
The flexible jacket provides complete enclosure of the conductors without requiring any slots or openings, thereby eliminating conductor exposure while still enabling flexibility and ease of installation through its inherent flexible material properties.
3Strength
If a thick rigid plastic cover is used, then conductor protection is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The flexible jacket made from thin plastic sheets provides adequate conductor protection while being simpler in construction and easier to assemble compared to thick rigid plastic covers, thereby reducing device complexity and assembly difficulty.
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 flexible jacket facilitates easier installation and maintains conductor alignment, providing a secure and flexible connection without exposing the conductors, enhancing the assembly process and system usability.
Implementation Method 1
an improved manufacturing process secures the jacket layers together using heat sealing or adhesives
Implementation Method 2
an improved manufacturing process secures the jacket layers together using heat sealing or adhesives
Data Source
AI summary
A modular power distribution system includes power distribution assemblies and flex connectors. The flex connector includes end connector housings and a flexible jacket that encloses conductor wires extending between the connectors. The jacket is formed from superimposed layers of sheet-like jacket material that is flexible. The bottom jacket layer is first laid on a bottom housing section wherein conductors are then placed thereupon with an upper jacket layer then positioned over the bottom jacket layer. The top and bottom jacket layers have aligned free edges along at least one side thereof wherein the free edges are bonded together such as by heat sealing.