Unitary Flexible Substrate Terminal Eliminates Wire Crimping
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Solution Overview
Problem
Current methods for connecting a terminal block to a flexible circuit require multiple connections, leading to inefficiencies, increased risk of connection failures, and potential damage to the copper wire due to crimping, which is time-consuming and costly.
Innovation Solution
A terminal with a connecting end, midsection, and crimping end formed as a single, unitary conductive component that directly connects to a housing and flexible substrate without wires, reducing the need for crimping and minimizing the risk of damage or failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal block system with wire crimp connections is used to connect to a flexible circuit, then electrical connection can be established, but the assembly process becomes time-consuming and the risk of connection failures increases
Solution Approach 1:
The patent merges the terminal body and the crimping element into a single unitary component. The terminal includes an integrated crimping portion that directly crimps the flexible circuit substrate without requiring separate wire crimping operations, thereby reducing the number of connection points and assembly steps while maintaining reliable electrical connection
Solution Approach 2:
The patent extracts the wire crimping step from the assembly process by designing a terminal that directly crimps the flexible circuit substrate. This eliminates the intermediate wire connection step, reducing both time and potential failure points in the assembly process
2Adaptability or versatility
If multiple connection points are used in the electrical circuit, then flexibility in connection methods is maintained, but the risk of connection failures increases
Solution Approach 1:
The patent combines multiple connection functions into a single terminal component. The unitary terminal structure integrates the electrical contact, insulation, and crimping functions, reducing the number of separate connection points while maintaining the ability to establish reliable electrical connections
3Reliability
If wire crimping operations are performed, then electrical connection is established, but the copper wire is prone to damage and the process becomes costly
Solution Approach 1:
The patent removes the separate wire crimping operation from the manufacturing process. The terminal is designed to directly crimp the flexible circuit substrate without requiring intermediate wire preparation, stripping, or crimping steps, thereby eliminating copper wire damage risks and reducing manufacturing complexity
Solution Approach 2:
The terminal structure includes self-aligning and self-crimping features that allow the crimping operation to be performed automatically during assembly without requiring separate manual wire preparation steps, reducing both complexity and potential for error
Data Source
AI summary
A terminal with a connecting end, a midsection, and a crimping end is disclosed. The midsection is adapted to prevent damage to the terminal. The connecting end is configured to be received in a housing. The crimping end is configured to be connected to a substrate. At least two of the connecting end, the midsection, and the crimping end are conductive and formed as a single, unitary component.