Folded Sheet Connector Assembly for Compact Low-Resistance Wiring
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Solution Overview
Problem
Existing connector assemblies for electrically connecting a conductor portion of an electric wire to a flexible conductor on a sheet type conductive member are bulky and have reliability issues due to separable connections and higher electric resistance.
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. The connector uses a folding-back mechanism to securely connect the electric wire to the flexible conductor, reducing size and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is used to connect an electric wire to a flexible conductor on a sheet type conductive member, then electrical connection is achieved, but the device size increases
Solution Approach 1:
The patent integrates the connector structure directly into the sheet type conductive member by forming a recessed portion in the sheet that accommodates the electric wire. The insulating sheet and conductive member are combined into a single integrated component, eliminating the need for separate connector parts and reducing overall device size while maintaining reliable electrical connection.
Solution Approach 2:
The electric wire is nested within the recessed portion formed in the sheet type conductive member. The insulating sheet is then folded back to cover and secure the wire within this recessed space, creating a compact nested structure that connects the wire to the flexible conductor without adding external bulk to the device.
2Ease of manufacture
If a separable connection structure is used between connectors, then assembly is simplified, but connection reliability deteriorates
Solution Approach 1:
The connector function is merged into the sheet type conductive member itself through the recessed portion structure. The insulating sheet is folded back and integrated with the conductive member to form a unified connection structure, eliminating separable connector components while maintaining ease of assembly through the simple folding and pressing operations.
Solution Approach 2:
The insulating sheet is used as a flexible thin film that is folded back to cover and secure the electric wire within the recessed portion. This flexible insulating film creates a reliable mechanical and electrical connection without requiring separate rigid connector parts, ensuring both assembly ease and connection reliability.
3Adaptability or versatility
If a flexible conductor is used to form an electric path from the measurement site to the connector, then connection flexibility is improved, but electric resistance increases
Solution Approach 1:
The electric path is segmented into two parts: a flexible conductor portion that provides adaptability and connection flexibility, and a low-resistance electric wire portion that is directly integrated into the sheet type conductive member through the recessed portion. This segmentation allows the flexible conductor to maintain its adaptability benefits while the integrated wire portion minimizes electric resistance for reliable signal transmission.
Data Source
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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.