Functional Contactor with Embedded Element for Mass Production
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Solution Overview
Problem
Conventional functional contactors for portable electronic devices face challenges in mass production due to complex bonding processes of conductive elastic portions with protective elements, leading to reduced manufacturing efficiency and increased risk of static electricity damage to internal circuits.
Innovation Solution
A functional contactor design that embeds a functional element within a substrate using a large-area substrate, allowing for efficient mass production by stacking conductive elastic portions and soldering them onto the substrate, which improves alignment and bonding efficiency while protecting the bonded portion from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual bonding of conductive elastic portion and protective element is performed, then bonding precision is achieved, but manufacturing efficiency deteriorates
Solution Approach 1:
The conductive elastic portion and protective element are merged into a single integrated component. The conductive elastic portion is formed as an integral part of the protective element, eliminating the need for separate bonding processes while maintaining electrical connection functionality and mechanical strength.
2Strength
If conventional bonding process is used, then bonding strength is achieved, but manufacturing time increases
Solution Approach 1:
The conductive elastic portion is pre-formed as an integral part of the protective element during the molding process. This preliminary formation eliminates subsequent bonding steps, reducing manufacturing time while ensuring consistent bonding strength through integrated construction.
3Ease of operation
If conductive elastic portion is exposed, then electrical contact function is achieved, but vulnerability to static electricity damage increases
Solution Approach 1:
The conductive elastic portion is nested within or protected by the protective element structure. The protective element serves as an outer shell that encloses or shields the conductive elastic portion, reducing direct exposure to static electricity while maintaining electrical contact capability through controlled interfaces.
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
This design enhances manufacturing efficiency, reduces production costs and time, and improves product reliability by embedding functional elements within the substrate, preventing external exposure and enhancing protection against static electricity and leakage currents.
Implementation Method 1
a conductive elastic portion configured to come into electrical contact with one among a circuit substrate of an electronic device, a bracket coupled to the circuit substrate, and a conductor contactable with a human body and having elasticity
Implementation Method 2
for an electrical contact between an antenna disposed in the external housing and the internal circuit substrate
Implementation Method 3
a substrate comprised of a plurality of dielectric layers
Implementation Method 4
during a process of bonding the conductive elastic portion to the protective element by soldering
Data Source
AI summary
A functional contactor is provided. The functional contactor contains a conductive elastic portion having elasticity and electrically contacting one of a circuit board of an electronic device, a bracket coupled to the circuit board, and a conductor which can come into contact with the human body; a substrate containing a plurality of dielectric layers; and a functional element embedded in the substrate so as to be electrically connected in series to the conductive elastic portion.