Fork Terminal Connection for Solder-Free Yarn Conductive Wires
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Solution Overview
Problem
Existing yarn conductive wires, which are made of yarn and metal wire, face challenges in connecting to circuit boards without losing stretchability and conductivity, especially when high-temperature processes like soldering are not feasible.
Innovation Solution
A quick connection structure and method using fork-shaped terminals with an accommodation space and interference fit with mounting holes on the circuit board, allowing the yarn conductive wire to be clamped and fixed without solder, utilizing friction forces for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect yarn conductive wire to circuit board, then electrical signal transmission is achieved, but the yarn conductive wire cannot withstand high temperatures and the process is complex and time-consuming
Solution Approach 1:
The patent introduces a fork-shaped terminal as an intermediary component between the yarn conductive wire and the circuit board. This terminal provides a mounting hole that mechanically secures the yarn conductive wire while maintaining electrical connectivity, thereby eliminating the need for high-temperature soldering processes.
Solution Approach 2:
The patent replaces the thermal-mechanical soldering process with a purely mechanical insertion method. The yarn conductive wire is simply inserted into the mounting hole of the fork-shaped terminal, which then connects to the circuit board through the mounting hole, eliminating complex high-temperature processing steps.
2Reliability
If soldering is used to connect yarn conductive wire to circuit board, then electrical signal transmission is achieved, but the process is time-consuming and not suitable for mass production
Solution Approach 1:
The fork-shaped terminal is pre-designed with a mounting hole of specific dimensions that are optimized for the yarn conductive wire. This preliminary preparation of the connection structure allows for rapid insertion and connection without requiring time-consuming soldering operations, thereby improving productivity for mass production.
3Ease of manufacture
If fork-shaped terminal with mounting hole is used, then yarn conductive wire can be quickly connected without solder, but the connection structure becomes more complex
Solution Approach 1:
The patent divides the connection system into distinct functional segments: the yarn conductive wire, the fork-shaped terminal, and the circuit board. This segmentation allows each component to be independently manufactured and optimized, with the fork-shaped terminal serving as a specialized connector that simplifies the overall assembly process despite adding a component.
4Strength
If interference fit is used between fork portion and mounting hole, then secure mechanical connection is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes interference fit by carefully controlling the dimensional parameters of the mounting hole and fork portion. The mounting hole diameter is designed to be slightly smaller than the fork portion outer diameter, creating a tight fit that provides strong mechanical connection. This parameter optimization allows achieving strong connections while maintaining reasonable manufacturing tolerances.
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
Enables quick, solder-free, and environmentally-friendly connection of yarn conductive wires to circuit boards, suitable for materials that cannot withstand high temperatures, facilitating mass production and maintaining conductivity.
Implementation Method 1
the fork portion of the fork-shaped terminal and the yarn conductive wire are pressed into the mounting hole of the circuit board, and the fork portion of the terminal and the mounting hole of the circuit board form an interference fit
Implementation Method 2
The yarn conductive wire is clamped in the fork portion of the fork-shaped terminal, so that the yarn conductive wire is connected and fixed to the circuit board
Data Source
AI summary
Quick connection structure and method for a yarn conductive wire and a circuit board are provided. The quick connection structure includes at least one yarn conductive wire, at least one fork-shaped terminal, and the circuit board. One end of the fork-shaped terminal has a fork portion. At least one mounting hole is formed on the circuit board, and the mounting hole penetrates two opposite sides of the circuit board. During assembly, the yarn conductive wire is inserted into a channel of a jig to allow the yarn conductive wire originally arranged horizontally to be arranged vertically. The fork-shaped terminal is pressed into the jig to cover the yarn conductive wire. The yarn conductive wire and the fork-shaped terminal are pressed into the mounting hole of the circuit board. A material tape of a row of the fork-shaped terminal is removed along a break line of the fork-shaped terminal.