Integrated Wire-to-Flexible Conductor Connector With Stable Contact
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Solution Overview
Problem
Existing connectors for connecting electric wires to flexible conductors on sheet-type conductive members are large in size and have unreliable electrical connections due to disconnectable sites, leading to high electric resistance and increased costs.
Innovation Solution
A connector design that includes insulators and a contact force-securing member to securely connect the electric wire conductor to the flexible conductor, reducing size and improving electrical reliability by ensuring a stable contact between the conductor portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector with two separate connectors (first connector and second connector) is used to connect an electric wire to a flexible conductor, then the connection can be established, but the device size is enlarged and the electrical connection reliability is reduced due to disconnectable sites
Solution Approach 1:
The patent merges the first connector and second connector into a single integrated connector body. The connector includes a housing with a first recess for receiving the flexible conductor and a second recess for receiving the electric wire, eliminating the need for separate connectors and their associated disconnectable connection sites, thereby improving reliability while reducing structural complexity
Solution Approach 2:
The patent employs a nested structure where the insulator is housed within the housing, the flexible conductor is received within the first recess, and the electric wire is received within the second recess. This nested arrangement allows multiple functional elements to be compactly integrated into a single connector unit, improving both reliability and space efficiency
2Ease of operation
If a connector with two separate connectors is used to connect an electric wire to a flexible conductor, then the connection can be established, but the device size is enlarged
Solution Approach 1:
The patent combines the functions of two separate connectors into a single integrated connector. The housing contains both the first recess for the flexible conductor and the second recess for the electric wire, maintaining full connection capability while significantly reducing the overall connector volume
Solution Approach 2:
The single connector housing serves multiple functions: it houses the insulator, receives the flexible conductor in the first recess, receives the electric wire in the second recess, and provides structural support. This multi-functional design eliminates the need for separate connectors, achieving ease of operation with compact size
3Reliability
If insulating materials are used in the connector, then electrical reliability is improved and water ingress is prevented, but the manufacturing complexity increases
Solution Approach 1:
The patent employs composite material construction where the housing and insulator are made from insulating materials that provide both electrical insulation and environmental sealing. This integrated material selection achieves superior electrical reliability and water ingress prevention while the unitary construction approach simplifies manufacturing compared to assembling multiple separate insulating components
Data Source
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AI summary
The connector includes a first insulator including a first retaining surface and a protrusion portion formed on and protruding from the first retaining surface, and a second insulator including a second retaining surface opposed to the first retaining surface and a recess portion formed in the second retaining surface and corresponding to the protrusion portion, the first insulator and the second insulator are connected to each other with the sheet type conductive member and the electric wire being held between the first retaining surface and the second retaining surface, and at least part of the protrusion portion is housed in the recess portion, whereby the conductor portion of the electric wire is electrically connected to the flexible conductor of the sheet type conductive member in the recess portion.