Wire-to-Substrate Connector With Sandwiched Contact Structure
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Solution Overview
Problem
Existing connectors for connecting electric wires to flexible conductors on substrates are large in size, unreliable, and require separatable connection portions, leading to high electric resistance and cost.
Innovation Solution
A connector design comprising a first and second insulator with recess and protrusion portions, and a conductive contact retained by both insulators, allowing the electric wire conductor to be sandwiched between recessed and protruding portions for reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector with separate first and second connectors is used to connect an electric wire to a flexible conductor, then the connection can be established, but the device size becomes larger and the connection reliability is impaired due to separatable connection portions
Solution Approach 1:
The patent combines the first connector (substrate connector) and second connector (wire connector) into a single integrated connector body. The insulator housing integrates both connection functions, with the first retained portion providing substrate connection and the second retained portion providing wire connection, eliminating the need for separate connectors and their separatable joints.
Solution Approach 2:
The connector is segmented into functional regions within a unified structure: the insulator body is divided into a first retained portion for substrate connection and a second retained portion for wire connection, allowing independent optimization of each connection interface while maintaining overall structural integrity and eliminating separatable joints.
2Length of moving object
If a conventional connector with separate first and second connectors is used, then the connection can be established, but the device size becomes larger
Solution Approach 1:
The patent merges the first and second connectors into a single compact insulator housing, reducing the overall connector size. The integrated structure eliminates the gap and separation between connectors, creating a more compact assembly while improving reliability through continuous structural support.
3Reliability
If a flexible conductor is used to form an electric circuit between the electrode and wearable device, then the connection can be established, but the electric resistance increases and cost increases
Solution Approach 1:
The patent introduces a rigid electric wire as an intermediary component between the electrode and wearable device, replacing the flexible conductor for the circuit connection. The connector serves as the intermediary coupling mechanism that joins the wire to the substrate, enabling low-resistance electrical connection while maintaining design flexibility.
Data Source
AI summary
A connector includes a first insulator having a recess portion, a second insulator having a protrusion portion, and a contact, the contact including a mounting portion mounted on a substrate, a first retained portion retained by the first insulator, a second retained portion retained by the second insulator, a deformable joint portion, and a connection portion connected to a conductive portion of the substrate, the first retained portion including a recessed bent portion accommodated in the recess portion, the first insulator and the second insulator being fitted to each other such that a conductor portion of an electric wire is sandwiched between the recessed bent portion of the first retained portion and the protrusion portion of the second insulator, the conductor portion of the electric wire making contact with the recessed bent portion to be electrically connected to the conductive portion of the substrate via the contact.