Snap Connectors for Stretchable Boards

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Solution Overview

Problem

Existing multiple-terminal electrical connectors are not intuitive for users, require precise alignment, and are not compatible with flexible or stretchable substrates, making them unsuitable for wearable and IoT applications where frequent attachment and detachment are necessary.

Innovation Solution

The development of multiple-terminal snap and zipper connectors that can easily mate and unmate with flexible substrates, featuring conductive interface terminals and a design that allows for easy assembly and disassembly without requiring specialized tools, enabling intuitive user operation and compatibility with stretchable materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing multiple-terminal electrical connectors are used, then electrical connections can be established, but they require precise alignment and fine manipulation which complicates operation

Engineering Contradiction:

Improveconnection reliabilityVSAvoiduser operation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector is divided into a header portion and a board portion that can be independently attached and detached. The header portion includes multiple terminal elements segmented into individual contact points, allowing each terminal to be independently engaged while maintaining overall connection reliability through the modular structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A compliant member acts as an intermediary between the terminal element and the board contact, providing tolerance for misalignment. The compliant member deformable structure absorbs positioning errors and ensures reliable electrical contact without requiring precise manual alignment, thereby improving ease of operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sophisticated snaps are used for stretchable skin contact applications, then multiple contacts can be established, but they consume large area and have large Z-height which impacts device discreteness and user comfort

Engineering Contradiction:

Improvecontact connection reliabilityVSAvoidsubstrate area consumption

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The terminal elements are arranged in a compact nested configuration where multiple contacts are stacked or layered within a small footprint. The header portion integrates multiple terminal elements vertically or in close proximity, significantly reducing the area consumed on the stretchable substrate while maintaining reliable multi-contact connections.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The connector transitions from a planar two-dimensional layout to a three-dimensional structure with vertical stacking of terminal elements. This dimensional change allows multiple contacts to be packed into a smaller substrate area by utilizing the Z-height dimension efficiently, reducing the footprint on the stretchable substrate.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If conventional electrical connectors are used, then electrical connections can be made, but they are not compatible with stretchable boards or substrates such as fabric

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidsubstrate compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The board portion of the connector is designed with flexible and stretchable characteristics, using compliant members and elastic materials that can deform with stretchable substrates like fabric. This flexibility allows the connector to maintain reliable electrical contact while accommodating the stretching and bending of the substrate, achieving compatibility with wearable applications.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The connector design incorporates variable mechanical properties through compliant members that can change their stiffness and deformability based on the substrate state. The compliant member structure allows the connector to adapt its physical parameters (flexibility, stretchability) to match the substrate, enabling reliable connections on both rigid and stretchable boards.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If thread through conductive rings are used, then permanent attachment is achieved, but the attach and detach process becomes complicated requiring thread cutting

Engineering Contradiction:

Improveattachment reliabilityVSAvoidattach and detach ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector employs a dynamic attachment mechanism where the header portion can be easily inserted into and removed from the board portion through a simple mating action. The compliant members provide automatic engagement and disengagement capabilities, allowing users to attach and detach the connector multiple times without complex operations or damage to the substrate, maintaining both reliability and ease of operation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS9893438B1Electrical connectors for high density attach to stretchable boards

Publication Date: 2018.02.13 INTEL CORP

AI summary

A system can include a first portion of a fabric fastener, a second portion of the fabric fastener, wherein the first portion and the second portion are configured to mechanically connect with each other and to resist separation from each other once connected, and wherein the first and second portions include a plurality of corresponding electrical contacts configured to form a plurality of individual electrical connections when the first portion is mechanically connected with the second portion.