Folded Sheet Connector Assembly for Low-Resistance Wire Joining
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Solution Overview
Problem
Existing connector assemblies for connecting electric wires to flexible conductors on sheet-type conductive members result in higher electric resistance, increased size, and reduced reliability due to separable connections and separate connectors.
Innovation Solution
A connector assembly comprising a sheet-type conductive member with a flexible conductor exposed on its surface, an electric wire with a conductor portion, and a connector that includes first and second insulators with retaining surfaces, allowing the electric wire to be passed through inserting holes and folded back to create a reliable electrical connection with the flexible conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate first connector and second connector are used to connect the electric wire to the flexible conductor, then the connection can be established, but the device size increases and reliability decreases due to the separable connection portion
Solution Approach 1:
The patent merges the first connector and second connector into a single integrated connector structure. The first insulator and second insulator are joined together to form one unified connector assembly, eliminating the separable connection between two separate connectors. This integration removes the connection interface between separate components, thereby improving reliability while reducing structural complexity.
2Reliability
If a separate first connector and second connector are used to connect the electric wire to the flexible conductor, then the connection can be established, but the device size increases
Solution Approach 1:
The patent merges the first connector and second connector into a single integrated connector structure. The first insulator and second insulator are joined together to form one unified connector assembly, eliminating the separable connection between two separate connectors. This integration removes the connection interface between separate components, thereby improving reliability while reducing structural complexity.
3Reliability
If the electric wire is connected to the flexible conductor using conventional connectors, then the connection can be made, but the electric resistance increases
Solution Approach 1:
The patent extracts and eliminates the intermediate connector components from the connection path. By directly joining the conductor portion of the electric wire to the flexible conductor through the integrated insulator structure, the patent removes unnecessary connection interfaces that would otherwise contribute to electric resistance. This direct connection approach reduces energy loss while maintaining connection stability.
Data Source
AI summary
A connector assembly includes a sheet type conductive member having a flexible conductor, an electric wire and a connector, the connector having a first insulator with a first retaining surface and a second insulator with a second retaining surface, the sheet type conductive member having a first sheet portion with a retained portion, a second sheet portion joined to the retained portion via a folding-back line and disposed to face the second retaining surface with the second sheet portion being folded back onto the retained portion along the folding-back line, and at least one electric wire inserting hole penetrating the sheet type conductive member, the conductor portion of the electric wire being passed through the electric wire inserting hole and disposed between the retained portion and the second sheet portion.