Spring Terminal Split-Blade Connector for Flexible Circuit Vibration
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Solution Overview
Problem
Conventional methods for connecting electrical devices to flat-wire conductors of flexible circuits face challenges such as vibration, misalignment, and debris interference, which can disrupt the physical and electrical connection.
Innovation Solution
An electrical connector with a spring terminal and a split-blade terminal is designed, where the spring terminal is configured to mate with flat-wire conductors using a compression force, allowing for flexibility in multiple degrees of freedom and improved alignment, and the split-blade terminal interfaces with electrical terminals, enabling secure and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crimping, welding, soldering, or stitching methods are used to create electrical connections, then effective electrical connection is achieved, but discrete leads must be separately terminated or spliced together which increases device complexity and manufacturing difficulty
Solution Approach 1:
The patent combines multiple terminal functions into a single integrated connector assembly. The spring terminal and split-blade terminal are merged into one unit that simultaneously provides both spring-loaded contact and blade interface capabilities, eliminating the need for separate discrete lead terminations while maintaining reliable electrical connection.
Solution Approach 2:
The connector is designed with multi-functional terminals that can handle different connection types. The spring terminal provides universal spring-loaded contact capability, while the split-blade terminal offers blade interface functionality, allowing a single connector to serve multiple connection purposes without requiring separate specialized components.
2Stability of the object's composition
If rigid connections are used to connect electrical devices to flat-wire conductors, then stable electrical connection is achieved, but the connection is vulnerable to vibration and misalignment disruptions
Solution Approach 1:
The spring terminal introduces dynamic flexibility to the connection system. Instead of a rigid fixed connection, the spring-loaded terminal can dynamically adjust its contact pressure and position, absorbing vibrations and accommodating misalignments while maintaining stable electrical connection throughout operational conditions.
Solution Approach 2:
The connector utilizes changes in contact force parameters through the spring mechanism. The spring terminal maintains optimal contact pressure by dynamically adjusting the force parameter in response to external disturbances like vibration, ensuring reliable connection without requiring rigid structural constraints.
3Manufacturing precision
If precise alignment is required for connecting terminals to flat-wire conductors, then connection accuracy is improved, but the connection becomes sensitive to misalignment and debris interference
Solution Approach 1:
The spring terminal acts as a flexible element that can deflect and adapt to minor misalignments and debris presence. This flexibility allows the terminal to maintain contact integrity even when perfect alignment is not achieved, reducing sensitivity to manufacturing tolerances and environmental contaminants.
Solution Approach 2:
The spring mechanism provides beforehand cushioning by maintaining constant contact pressure and accommodating position variations. This pre-loaded spring force creates a cushioning effect that protects the connection from being disrupted by debris or minor misalignments, ensuring reliable operation without requiring extremely precise alignment.
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
The electrical connector provides a robust and reliable connection that withstands vibration and misalignment, maintains contact integrity despite debris, and facilitates easy automation, ensuring consistent electrical performance.
Implementation Method 1
One or more of the plurality of spring terminals abut the exposed section of one or more of the flat-wire conductors based on a compression force
Data Source
AI summary
An electrical connector for connecting to flat-wire conductors of a flexible circuit (FC) is described. The electrical connector includes an elongated body, a split-blade terminal, and a spring terminal. The elongated body has a longitudinal axis. The split-blade terminal has two prongs separated by a distance and is configured to interface with an electrical terminal of an electrical device. The spring terminal is configured to mate with one or more of the flat-wire conductors within a connection area of the FC. The spring terminal and the split-blade terminal are positioned on the longitudinal axis at opposing ends of the electrical connector.