Terminal Module Laminate for Connector Flexibility and Breakage Resistance
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Solution Overview
Problem
Existing connectors face issues with the fragility of braided wires used for electrical connections, leading to breakage when other components rub against them, and the need to reduce the number of components to lower costs.
Innovation Solution
A terminal module with a resilient member and an electrically conductive laminate formed by laminating thin plates, where the laminate includes integrated and non-integrated regions to provide necessary stiffness and flexibility, replacing the conventional electrical contact member, external connecting member, and braided wire with a single laminate, reducing the risk of breakage and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a braided wire is used to electrically connect the electrical contact member and the external connecting member, then flexibility and electrical connection are achieved, but the braided wire is fragile and easily broken when other members rub against it
Solution Approach 1:
The patent combines the electrical contact member, external connecting member, and flexible connection function into a single laminate structure. The laminate includes an integrated region where multiple thin plates are integrated in the thickness direction to provide strength, and a non-integrated region where plates are not integrated to provide flexibility. This merging eliminates the separate braided wire component while maintaining both flexibility and breakage resistance.
Solution Approach 2:
The laminate is formed by laminating multiple thin plates together, creating a composite structure. The integrated region provides high strength and rigidity to prevent breakage, while the non-integrated region provides flexibility for movement. This composite approach replaces the braided wire's flexible connection function with a more durable laminate structure.
2Adaptability or versatility
If multiple separate components (electrical contact member, external connecting member, braided wire) are used, then functional requirements are met, but the number of components increases cost and complexity
Solution Approach 1:
The patent merges three separate components (electrical contact member, external connecting member, and braided wire) into a single laminate structure. The laminate integrates the electrical contact function, external connection function, and flexible movement function that were previously distributed across multiple components, thereby reducing part count and cost while maintaining all necessary functionalities.
Solution Approach 2:
The laminate is designed to perform multiple functions simultaneously: it provides electrical contact, external connection, and flexible movement accommodation. The integrated region handles structural and electrical functions, while the non-integrated region handles flexibility, making the laminate a multi-functional component that replaces several separate parts.
3Strength
If the laminate is fully integrated in the thickness direction, then strength and stiffness are maximized, but flexibility and ability to deflect are reduced
Solution Approach 1:
The laminate employs different structural qualities in different regions: the integrated region has high strength and rigidity for structural support and electrical contact, while the non-integrated region has high flexibility for movement and deflection. This local differentiation allows each region to optimize its properties for its specific function, achieving both strength and flexibility in the overall structure.
Solution Approach 2:
The laminate is segmented into distinct functional regions: an integrated region where thin plates are bonded together to provide strength, and a non-integrated region where plates remain separate to provide flexibility. This segmentation allows the structure to have both rigid and flexible portions, enabling it to maintain strength while accommodating movement and deflection.
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 solution effectively reduces the cost of connectors while minimizing the risk of member breakage by integrating the functions of multiple components into a single laminate, enhancing durability and maintaining necessary stiffness for reliable electrical connections.
Implementation Method 1
a resilient member to be accommodated into the case, the resilient member being stretchable along the first direction
Implementation Method 2
the flexible region being deflected when the first terminal region moves toward the other side
Data Source
AI summary
A terminal module to be electrically connected to a mating connector by being fit to the mating connector relatively approaching along a first direction from one side toward another side is provided with a case including a ceiling wall and a pair of side walls extending toward the one side from the ceiling wall, a resilient member to be accommodated into the case and stretchable along the first direction, and an electrically conductive laminate formed by laminating a plurality of thin plates. The laminate includes a first terminal region supported on the pair of side walls while being biased toward the one side by the resilient member a second terminal region located away from the first terminal region toward the other side, and a flexible region located between the first and second terminal regions and to be deflected when the first terminal region moves toward the other side.