Intermediary Connector for Flexible Assembly Repair
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Solution Overview
Problem
Existing methods for attaching flexible electrical assemblies to rigid assemblies, such as circuit boards, in high vibration environments often result in permanent connections that are difficult and costly to repair when failures occur, requiring complete replacement of both assemblies.
Innovation Solution
An intermediary device with an insulator core and removably secured electrical contacts is used to connect flexible and rigid assemblies, allowing for non-destructive disengagement and replacement without soldering, providing a standardized interface for increased usability and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If permanent attachment methods (such as soldering) are used to connect flexible assembly to rigid assembly, then connection strength is improved, but ease of repair deteriorates
Solution Approach 1:
The invention divides the connection system into three separate segments: the rigid assembly, the intermediary device, and the flexible assembly. This segmentation allows the flexible assembly to be disconnected and replaced without affecting the rigid assembly, enabling easy repair while maintaining strong connections through the intermediary device's multiple electrical contacts.
Solution Approach 2:
The intermediary device serves as a mediator between the rigid assembly and the flexible assembly. It provides a standardized connector interface that maintains strong electrical connections while allowing the flexible assembly to be easily disconnected and replaced, thus resolving the contradiction between connection strength and ease of repair.
2Reliability
If permanent attachment methods are used, then reliability is improved, but device complexity increases
Solution Approach 1:
The intermediary device provides a universal standardized connector interface that can accommodate different flexible assemblies. This multi-functionality allows the same intermediary device to work with various flexible assemblies, maintaining reliability while avoiding the need for complex custom soldering procedures for each specific assembly.
3Reliability
If complete replacement of both assemblies is required when failure occurs, then reliability is maintained, but loss of time increases
Solution Approach 1:
By segmenting the connection system into replaceable components with the intermediary device as the stable anchor, the invention enables replacement of only the flexible assembly when it fails, rather than requiring replacement of both the flexible assembly and the rigid assembly, thus reducing downtime.
4Reliability
If complete replacement of both assemblies is required, then reliability is maintained, but cost increases
Solution Approach 1:
The segmentation enabled by the intermediary device allows selective replacement of only the failed flexible assembly while retaining the functional rigid assembly and intermediary device, thereby reducing material waste and repair costs while maintaining system reliability.
Data Source
AI summary
An electrical assembly connector for connecting a flexible assembly having a plurality of flexible assembly electrical contacts to a rigid assembly having a connector receptacle with a plurality of attachment element electrical contacts. The connector comprises an intermediary device configured to electrically connect the rigid assembly and the flexible assembly. The intermediary device has a plurality of connector electrical contacts. The intermediary device electrical contacts are exposed on a first base side and on a second base side of the intermediary device. The intermediary device electrical contacts exposed on the second base side are configured to mechanically and electrically couple to the flexible assembly electrical contacts, and the intermediary device electrical contacts exposed on the first base side are configured to electrically and mechanically couple to the attachment element electrical contacts.