Flexible Wiring Body Connection Structure with Stress Distribution
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Solution Overview
Problem
Existing methods for connecting flexible wiring bodies made of elastomers to circuit boards face reliability issues due to mechanical stress and breakage during extension and contraction, as well as difficulties in maintaining a stable connection with existing connectors.
Innovation Solution
A wiring body connection structure that uses a laminated section with a conductive adhesive layer and a cover member to bond the first and second wiring bodies, allowing for indirect connection to a circuit board connector, thereby distributing stress and preventing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flexible wiring body made of elastomer is directly connected to an existing connector through mechanical biting, then the connection can be established, but the wiring body may break or cracking may occur due to small mechanical strength and repeated extension/contraction
Solution Approach 1:
A rigid support plate is introduced as an intermediary component between the flexible wiring body and the connector. The support plate receives the mechanical biting force from the connector's electrode and distributes it across a broader area, preventing stress concentration that would cause wiring breakage. This mediator allows the flexible wiring to maintain its elasticity while providing a stable connection interface.
Solution Approach 2:
The connection structure combines the flexible elastomer wiring body with a rigid support plate to create a composite assembly. This composite structure leverages the flexibility of the elastomer for movement while utilizing the rigidity of the support plate for mechanical strength and stress distribution, resolving the contradiction between flexibility and mechanical durability.
2Adaptability or versatility
If the wiring body extends and contracts following deformation, then flexibility is achieved, but settling occurs in the wiring due to compression set of the elastomer, causing connection failure
Solution Approach 1:
The connection structure is segmented into distinct functional zones: the flexible wiring body for movement, the rigid support plate for structural stability, and the connection interface for electrical contact. This segmentation allows each component to perform its specialized function - the wiring can settle and deform without affecting the overall connection stability maintained by the rigid support plate.
3Ease of manufacture
If existing wiring bodies like FFC or FPC are used for indirect connection, then connection to circuit board is achieved, but the wiring body may break during fabrication due to peeling force at the forefront
Solution Approach 1:
The rigid support plate is positioned beforehand at the forefront of the wiring body to provide cushioning and protection. During fabrication processes such as lamination and pressurization, the support plate absorbs and distributes the applied forces, preventing the peeling and breaking that would otherwise occur at the vulnerable forefront of the flexible wiring body.
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 provides a reliable and cost-effective connection that prevents breakage of the flexible wiring during use and fabrication, ensuring high durability and ease of downsizing and thinning of the connection structure.
Implementation Method 1
a conductive adhesive layer bonding the first end and the second end in the laminated section while ensuring a conductive property
Data Source
AI summary
A wiring body connection structure includes a first wiring body and a second wiring body, the first wiring body having a first base material made of an elastomer and a first wiring containing an elastomer and a conductive material, the second wiring body having a second base material and a second wiring. In the wiring body connection structure, a laminated section is partitioned where a first end of the first wiring body and a second end of the second wiring body overlap in a front-rear direction. The wiring body connection structure further includes a cover member arranged on a front surface of the first wiring body, and a conductive adhesive layer bonding the first end and the second end in the laminated section while ensuring a conductive property. The cover member is interposed between a frontmost end of the second end and the first wiring in the laminated section.