Terminal Module Flex Conductor Layout for Compact Reliable Connectors

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Solution Overview

Problem

Existing connectors that use flexible conductors for electrical connections face disconnection issues due to rubbing against housing components, leading to increased size and space requirements to accommodate unpredictable flexing, which hinders space-saving designs.

Innovation Solution

A terminal module with a flexible conductor configuration that includes a first terminal, a second terminal, and a flexible conductor with a joint portion connected to both, where the intermediate part flexes to protrude inwardly, allowing the flexible conductor's movement range to be accommodated within a smaller space, reducing rubbing against the housing and preventing disconnection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible conductor is used to connect the electrical contact member and external connection member, then the electrical contact member can move while maintaining electrical connection, but the flexible conductor may rub against housing components causing disconnection

Engineering Contradiction:

Improvemovement capabilityVSAvoidconnection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent pre-defines the movement path of the flexible conductor by positioning it between the housing and the electrical contact member before assembly. This preliminary positioning ensures that during operation, the flexible conductor follows a predetermined path that avoids contact with housing components, preventing rubbing and disconnection while maintaining movement capability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces the housing as an intermediary element that acts as a guide or barrier. By positioning the flexible conductor between the housing and the electrical contact member, the housing serves as a mediator that directs the flexible conductor's movement path, preventing it from rubbing against other housing components while still allowing necessary movement

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If space is provided for the flexible conductor to flex, then disconnection is prevented, but the connector size increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent applies local quality by providing space for flexible conductor movement only in specific localized areas between the housing and electrical contact member, rather than providing uniform space throughout the entire connector. This allows the flexible conductor to flex where needed while maintaining a compact overall connector size in non-critical areas

Inventive Principle:

Principle #3Local quality

3Volume of moving object

If the flexible conductor is constrained to move within a smaller space, then connector size is reduced, but the conductor may rub against housing components

Engineering Contradiction:

Improveconnector sizeVSAvoidrubbing and disconnection risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent resolves the space conflict by utilizing the third dimension - positioning the flexible conductor in the space between the housing and electrical contact member along the insertion direction. This vertical positioning allows the flexible conductor to move within a compact horizontal footprint while avoiding rubbing against housing components through proper vertical clearance

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 configuration enables the downsizing of connectors while maintaining reliable electrical connections by predicting and managing the flexible conductor's movement, reducing the risk of disconnection and space requirements.

Implementation Method 1

an elastic member that extends from the ceiling wall toward the first side; a first terminal that is supported on the pair of side walls in a state where the first terminal is biased toward the first side by the elastic member

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a flexible conductor that electrically connects the first terminal and the second terminal, wherein the first terminal includes: a first part that is provided on the first side of the elastic member

Methodology Applied

Scientific EffectFlexing: Elasticity

Data Source

PatentUS20240120674A1Terminal module and connector

Publication Date: 2024.04.11 SUMITOMO WIRING SYSTEMS LTD

AI summary

A terminal module mates to a mating connector that relatively approaches the terminal module from a first side to a second side along a first direction (z direction) and electrically connects to the mating connector. The terminal module includes a first terminal provided so as to be movable toward the second side by being pressed by the mating connector; a second terminal that is positioned at a distance from the first terminal in a second direction (x direction) that is perpendicular to the first direction; and a flexible conductor that electrically connects the first terminal and the second terminal. The first terminal includes a first part that is provided so as to be capable of contacting the mating connector and a second part that extends from a second terminal side end of the first part toward the first side or the second side.