Electric connector and method for assembling electric connector

Abstract

A method (200) for assembling an electrical connector (100) includes providing an insulated flexible flat cable (102) having a plurality of electrical conductors (104), inserting the flat cable (101) into a connector housing (114) and a terminal housing (106), attaching an electrical terminal (110) to the conductors (104), pulling the flat cable (102) to pull the terminal (110) into a terminal cavity (108) in the terminal housing (110), and assembling the electrical connector (100). And further pulling the flat cable (102) to pull the terminal housing (110) into the connector housing (114). The method (200) simplifies the assembly process of the electrical connector (100) and ensures secure connection between the conductor (102) and the terminal (110) within the housing structure (110, 114).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. patent application No. 18 / 228,859, filed on August 1, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0001] The present invention generally relates to a method of assembling an electrical connector and an electrical connector assembly, such as an electrical connector assembly produced using such a method. Background Art

[0002] The desire to provide electrical connection systems that are easier to assemble using automated processing methods and easier to route in vehicles has led to a shift in automobiles and other vehicles from traditional round wiring harnesses to flat wiring harnesses.

[0003] The traditional method of assembling electrical connectors involves manually attaching electrical terminals to individual conductors of a flat cable and then inserting the cable and terminal into separate housings. This process typically requires precise alignment and manual labor, making it time consuming and error prone. In addition, inserting the flat cable into the terminal housing and then into the connector housing typically involves multiple steps, adding to the complexity of the assembly process.

[0004] In some prior art, electrical terminals are attached to conductors within flat cables using crimping tools or welding techniques. While these methods can provide a secure connection between the terminal and the conductor, they can require specialized equipment and skilled operators. In addition, the subsequent insertion of the flat cable into the terminal housing and connector housing can involve separate operations, resulting in potential misalignment or inconsistency in the final assembly.

[0005] Other approaches in the field of electrical connector assembly focus on improving the efficiency of the process by utilizing automated machinery or robots to handle insertion and attachment tasks. However, these automated systems may still face challenges in ensuring precise alignment of components and maintaining the integrity of the electrical connection throughout the assembly process. Overall, existing methods of assembling electrical connectors typically involve multiple manual or semi-automated steps, resulting in inefficiencies and potential end-product quality issues.

[0006] However, none of these approaches provide a comprehensive solution incorporating the features described in the present disclosure. Summary of the invention

[0007] According to one or more aspects of the present disclosure, a method for assembling an electrical connector includes the following steps: (a) providing an insulated flexible flat cable having a plurality of electrical conductors; (b) inserting the flat cable into the connector housing; (c) inserting the flat cable into the terminal housing; (d) attaching a plurality of electrical terminals to a plurality of electrical conductors; (e) pulling the flat cable to draw the plurality of electrical terminals into the plurality of terminal cavities defined in the terminal housing; and (f) Pull the flat cable to further pull the terminal housing into the connector housing.

[0008] In some aspects of the method described in the previous paragraph, the plurality of electrical terminals are formed from expanded sheet metal. The method may also include the following steps: (h) Attaching a plurality of electrical terminals to the plurality of electrical conductors.

[0009] In certain aspects of the method described in any of the preceding paragraphs, the plurality of electrical conductors have a substantially rectangular cross-section. The method may further include the steps of: (i) removing insulation from ends of the plurality of electrical conductors, thereby exposing portions of the plurality of electrical conductors; and (j) Folding the plurality of electrical conductors over edges of the plurality of electrical terminals.

[0010] In certain aspects of the method described in any of the preceding paragraphs, the plurality of electrical terminals are selected from a list consisting of male blade terminals and female tuning fork terminals.

[0011] In certain aspects of the method described in any of the preceding paragraphs, the terminal housing includes a seal from the terminal housing to the connector housing. The method may further include the following steps: (k) inserting the flat cable into the cable-to-terminal housing seal; and (l) Pull the flat cable to pull the terminal housing seal into the sealed cavity defined in the terminal housing.

[0012] In certain aspects of the methods described in the preceding paragraph, step (i) occurs before step (c).

[0013] In some aspects of the method of any of the preceding paragraphs, the method may further include the following steps: (m) Attach the terminal cap to the terminal housing.

[0014] In certain aspects of the method described in any of the preceding paragraphs, the terminal cap defines a plurality of rectangular protrusions located between the plurality of electrical terminals. The terminal housing defines a plurality of slots located between the plurality of electrical terminals, the plurality of rectangular protrusions being received in the slots.

[0015] In some aspects of the method of any of the preceding paragraphs, the method may further include the following steps: (n) removing insulation from ends of the plurality of electrical conductors, thereby exposing portions of the plurality of electrical conductors; (o) cutting notches in the insulation between exposed portions of the plurality of electrical conductors; and (p) The ends of the plurality of rectangular protrusions are placed in the recesses.

[0016] According to one or more aspects of the present disclosure, an electrical connector is manufactured by a process comprising the following steps: (a) providing an insulated flexible flat cable having a plurality of electrical conductors; (b) inserting the flat cable into the connector housing; (c) inserting the flat cable into the terminal housing; (d) attaching a plurality of electrical terminals to a plurality of electrical conductors; (e) pulling the flat cable to draw the plurality of electrical terminals into the plurality of terminal cavities defined in the terminal housing; and (f) Pull the flat cable to further pull the terminal housing into the connector housing.

[0017] In some aspects of the electrical connector described in the previous paragraph, the plurality of electrical terminals are formed from expanded sheet metal. The process may also include the following steps: (h) Attaching a plurality of electrical terminals to the plurality of electrical conductors.

[0018] In certain aspects of the electrical connector described in any of the preceding paragraphs, the plurality of electrical conductors have a substantially rectangular cross-section. The process may further include the following steps: (i) removing insulation from ends of the plurality of electrical conductors, thereby exposing portions of the plurality of electrical conductors; and (j) Folding the plurality of electrical conductors over edges of the plurality of electrical terminals.

[0019] In certain aspects of the electrical connector described in any of the preceding paragraphs, the plurality of electrical terminals are selected from a list consisting of male blade terminals and female tuning fork terminals.

[0020] In certain aspects of the electrical connector described in any of the preceding paragraphs, the terminal housing includes a seal from the terminal housing to the connector housing. The process may also include the following steps: (k) inserting the flat cable into the cable-to-terminal housing seal; and (l) Pull the flat cable to pull the terminal housing seal into the sealed cavity defined in the terminal housing.

[0021] In certain aspects of the electrical connector described in the preceding paragraph, step (i) occurs before step (c).

[0022] In some aspects of the electrical connector described in any of the preceding paragraphs, the process flow may further include the following steps: (m) Attach the terminal cap to the terminal housing.

[0023] In certain aspects of the method described in any of the preceding paragraphs, the terminal cap defines a plurality of rectangular protrusions located between the plurality of electrical terminals. The terminal housing defines a plurality of slots located between the plurality of electrical terminals, the plurality of rectangular protrusions being received in the slots.

[0024] In some aspects of the electrical connector described in any of the preceding paragraphs, the process flow may further include the following steps: (n) removing insulation from ends of the plurality of electrical conductors, thereby exposing portions of the plurality of electrical conductors; (o) cutting notches in the insulation between exposed portions of the plurality of electrical conductors; and (p) The ends of the plurality of rectangular protrusions are placed in the recesses.

[0025] According to one or more aspects of the present disclosure, an electrical connector assembly includes an insulated flexible flat cable having a plurality of electrical conductors. A portion of each of the plurality of electrical conductors is exposed; a plurality of electrical terminals are formed by unfolded sheet metal plates and attached to the plurality of electrical conductors. The plurality of electrical conductors are folded over the edges of the exposed portions of the plurality of electrical conductors. The electrical connector assembly also includes a terminal housing and a terminal cap attached to one end of the terminal housing, the terminal housing having a plurality of terminal cavities in which the plurality of electrical terminals are disposed. The electrical connector assembly also includes a connector housing in which the terminal housing is disposed.

[0026] In some aspects of the electrical connector assembly described in the preceding paragraph, the terminal cap defines a plurality of rectangular protrusions between the plurality of electrical terminals, wherein the terminal housing defines a plurality of slots between the plurality of electrical terminals, the plurality of rectangular protrusions being received in the slots.

[0027] In some aspects of the electrical connector assembly described in the preceding paragraph, the flat cable defines a recess in the insulation between exposed portions of the plurality of electrical conductors, and ends of the plurality of rectangular protrusions are disposed within the recess.

[0028] In certain aspects of the electrical connector assembly described in any of the preceding paragraphs, the plurality of electrical terminals are selected from the list consisting of male blade terminals and female tuning fork terminals. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0030] Figure 1 is an isometric view of an electrical connector according to some embodiments;

[0031] Figure 2 According to some embodiments Figure 1 An isometric view of a cable with a connector assembly;

[0032] Figure 3 According to some embodiments Figure 1 An isometric view of a subassembly of an electrical connector, wherein Figure 2 The cable is inserted into the connector housing;

[0033] Figure 4 According to some embodiments Figure 1 An isometric view of a subassembly of an electrical connector with a cable seal placed Figure 3 On the cables on the subassemblies;

[0034] Figure 5 According to some embodiments Figure 1 An isometric view of a subassembly of an electrical connector in which the terminal housing is placed Figure 4 On the cables on the subassemblies;

[0035] Figure 6 According to some embodiments Figure 1 An isometric view of a subassembly of an electrical connector, wherein Figure 5 The cables of the subassemblies are stripped of insulation to expose the conductors;

[0036] Figure 7 is an isometric view of an electrical terminal retained in a fixture according to some embodiments;

[0037] Figure 8 According to some embodiments, Figure 7 An isometric view of an electrical terminal in a fixture attached to Figure 5 Exposed conductors of subassemblies;

[0038] Fig. 9 According to some embodiments Figure 8 an isometric view of an exposed conductor folded over an electrical terminal;

[0039] Fig.10 In one embodiment of the present invention, Figure 1 The electrical connector subassembly where the cable and electrical terminals are pulled to Figure 6 an isometric view of the subassembly after being inside the terminal housing;

[0040] Fig.11 In one embodiment of the present invention, Figure 1 The terminal housing of the electrical connector subassembly is pulled to Fig.10 an isometric view of the subassembly after being inside the connector housing;

[0041] Fig.12 yes Figure 1 An exploded isometric view of an electrical connector of the present invention is shown in FIG. Fig.11 a subassembly of and a terminal cap configured to be attached to a terminal housing;

[0042] Fig.13A and Fig. 13B is a flow chart of a method of assembling an electrical connector according to some embodiments. DETAILED DESCRIPTION

[0043] Figure 1 The non-limiting example of the electrical connector 100 shown in the figure includes: an insulated flexible flat cable 102 having a plurality of electrical conductors 104; a terminal housing 106 having a plurality of terminal cavities 108 in which a plurality of electrical terminals 110 are disposed; a terminal cap 112 attached to one end of the terminal housing 106; and a connector housing 114 in which the terminal housing 106 is disposed.

[0044] The steps of the non-limiting method 200 of assembling the electrical connector 100 are as follows: Figures 2 to 12 In step 202 of method 200, providing Figure 2 The flat cable 102 shown. In this example, the flat cable includes electrical conductors 104 having a rectangular cross-section, which are bounded by a single insulating sheath, such as the electrical conductors in a flat flexible cable (FFC) or a flexible printed circuit (FPC). Alternatively, the electrical conductors can have a square, round or oval cross-section, such as the electrical conductors in a ribbon cable. In another alternative, the flat cable can be replaced by a cable formed by a bundle of individually insulated electrical conductors.

[0045] In step 204 of method 200, the flat cable 102 is inserted into the connector housing 114, such as Figure 3 As shown, the connector housing 114 has openings at both ends and defines a connector cavity therein.

[0046] like Figure 4 As shown, the cable seal 116 is placed on the flat cable 102, which corresponds to step 222 of the method 200. The cable seal 116 may be stretched, or a lubricant may be applied to the flat cable 102 and / or the cable seal 114 to facilitate sliding of the cable seal 116 on the flat cable 102. If the electrical connector is used in a non-sealed application, step 222 may be eliminated.

[0047] In step 206 of method 200, the flat cable 102 is Figure 5 The terminal housing 106 is inserted into the terminal housing 106 as shown. The terminal housing 106 has a plurality of terminal cavities 108 and a cable cavity (not shown) extending through the terminal housing 106. Figure 5The illustrated terminal housing 106 also includes a terminal housing seal 118 that is pulled into a sealed cavity (not shown) of the connector housing 112 by pulling the flat cable 102 in accordance with step 224 of method 200. The terminal housing seal 118 may be eliminated if the electrical connector is used in an unsealed application.

[0048] According to step 218 or 228 of method 200, Figure 6 The insulation 120 of the flat cable 102 is shown removed from the ends of the electrical conductors 104, thereby providing exposed portions 122 of the electrical conductors 104. In addition, according to step 230 of the method 200, notches 126 are cut in the insulation 120 between the exposed portions 122. Preferably, step 220 or 228 is performed before performing step 206 of the method 200.

[0049] In step 214 of method 200, the electrical terminal 110 may be placed into a fixture 128 configured to hold the electrical terminal 110 in place while the electrical terminal 110 is attached to the exposed portion 122 of the electrical conductor 104, such as Figure 7 As shown. The electrical terminal 110 shown here is a female tuning fork terminal formed from an expanded sheet metal. Alternatively, the terminal can be a male blade terminal formed from an expanded sheet metal. In another alternative, the terminal can be a socket or pin terminal formed by any number of metal forming process methods.

[0050] like Figure 8 As shown, the exposed portion 122 of the electrical conductor 104 is placed on the attachment portion 130 of the electrical terminal 110 and attached to the attachment portion 30 according to step 208 of the method 200. This is preferably achieved by a welding process, such as laser welding, ultrasonic welding, sintering or soldering. Alternatively, a conductive adhesive or mechanical crimping process can be used to attach the exposed portion 122 to the attachment portion 130. Fig. 9 As shown, the exposed portion 122 of the electrical conductor 104 is folded over the edge 132 of the attachment portion 130 to increase the contact surface area between the electrical conductor 104 and the electrical terminal 110 .

[0051] In step 210 of method 200, as Fig.10 As shown, the electrical terminal 110 has been removed from the clamp 128 , and the flat cable 102 is pulled to draw the electrical terminal 110 into the terminal cavity 108 in the terminal housing 106 .

[0052] In step 212 of method 200, as Fig.11The flat cable 102 is shown being further pulled to draw the terminal housing seal 118 into a sealed cavity (not shown) defined in the terminal housing 106 , and the flat cable 102 is further pulled to draw the terminal housing 106 into the connector housing 114 .

[0053] In step 226 of method 200, a terminal cap 112 configured to retain the electrical terminal 110 within the terminal cavity 108 is attached to one end of the terminal housing 106. The terminal cap 112 defines a Fig.12 A plurality of rectangular protrusions 134 are shown, which are formed of an electrically insulating material and are inserted between the electrical terminals 110. The terminal housing 106 defines a plurality of slots 136. The slots 136 are located between the electrical terminals 110, and the rectangular protrusions 134 are received in these slots 136. According to step 232 of the method 200, the ends of the rectangular protrusions 134 are received in the recesses 126 in the insulating member 120. These rectangular protrusions 134 electrically insulate the electrical terminals 110 from each other, and the recesses 126 provide a tortuous path between the electrical terminals 110, thereby increasing the creepage distance required for high voltage applications, such as greater than 48 volts. In low voltage applications of the electrical connector 100, such as less than 48 volts, the protrusions and recesses can be eliminated.

[0054] The flowchart of the method 200 for assembling the electrical connector 100 is shown in FIG. Fig.13A and Fig. 13B shown.

[0055] Although the present invention has been described according to the preferred embodiments of the present invention, the present invention is not intended to be limited thereto, but is only limited by the scope set forth in the following claims. For example, the embodiments described above (and / or their various aspects) can be used in combination with each other. In addition, various modifications can be made to adapt specific situations or materials to the teachings of the present invention without departing from its main scope. The dimensions, types, orientations of the various components described herein, and the number and position of the various components are intended to define the parameters of a specific embodiment, are not meant to be limiting, and are only prototype embodiments.

[0056] After reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art. Therefore, the scope of the present invention is limited only by the appended claims and the full scope of equivalents encompassed by these claims.

[0057] As used herein, “one or more” includes a function performed by one element, a function performed by more than one element, such as in a distributed fashion, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0058] It should also be understood that, although in some cases, the terms first, second, etc. are used to describe various elements in this article, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the various described embodiments, the first contact can be referred to as the second contact, and similarly, the second contact can be referred to as the first contact. Both the first contact and the second contact are contacts, but they are not identical contacts.

[0059] The terms used in the description of the various embodiments herein are only for the purpose of describing specific embodiments and are not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and encompasses all possible combinations of one or more associated listed items. It should also be understood that the terms "comprise", "contain", "include" and / or "include" used in this specification specifically refer to the presence of stated features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or their groups.

[0060] As used herein, the term "if" may be alternatively interpreted as "when" or "in" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if it is determined" or "if [the state or event] is detected" may be alternatively interpreted as meaning "upon determining" or "in response to determining" or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]", depending on the context.

[0061] In addition, although the terms of regulations or directions may be used herein, these elements should not be limited by these terms. Unless otherwise specified, all regulations or directions are used to distinguish one element from another element, and unless otherwise specified, do not represent any particular order, order of operation, direction or orientation.

Claims

1. A method (200) of assembling an electrical connector (100), comprising: a) providing an insulated flexible flat cable (102) having a plurality of electrical conductors (104); b) inserting the flat cable (102) into a connector housing (114); c) inserting the flat cable (102) into a terminal housing (106); d) attaching a plurality of electrical terminals (110) to the plurality of electrical conductors (104); e) pulling the flat cable (102) to pull the plurality of electrical terminals (110) into a plurality of terminal cavities (108) defined in the terminal housing (106); and f) pulling the flat cable (102) to further pull the terminal housing (106) into the connector housing (114).

2. The method (200) according to claim 1, characterized in that: The plurality of electrical terminals (110) are formed from unfolded sheet metal, wherein the method (100) further comprises: g) attaching the plurality of electrical terminals (110) to the plurality of electrical conductors (104).

3. The method (200) according to claim 2, characterized in that: The plurality of electrical conductors (104) have a substantially rectangular cross-section, wherein the method (100) further comprises: h) removing insulation (120) from ends of the plurality of electrical conductors (104) to expose portions of the plurality of electrical conductors (104); and i) folding the plurality of electrical conductors (104) over edges (132) of the plurality of electrical terminals (110).

4. The method (200) according to claim 2, characterized in that: The plurality of electrical terminals (110) are selected from a list consisting of male blade terminals and female tuning fork terminals.

5. The method (200) according to claim 1, characterized in that: The terminal housing (106) includes a seal from the terminal housing (106) to the connector housing (114), wherein the method (200) further includes: j) inserting the flat cable (102) into a cable-to-terminal housing (106) seal (118); and k) pulling the flat cable (102) to draw the terminal housing (106) seal (118) into a sealed cavity defined in the terminal housing (102).

6. The method (200) according to claim 5, characterized in that: Step j) occurs before step c).

7. The method (200) according to claim 1, characterized in that: The method (200) further comprises: 1) Attaching a terminal cap (112) to the terminal housing (106).

8. The method (200) according to claim 7, characterized in that: The terminal cap (112) defines a plurality of rectangular protrusions (134) located between the plurality of electrical terminals (110), wherein the terminal housing (106) defines a plurality of grooves (136) located between the plurality of electrical terminals (110), and the plurality of rectangular protrusions (134) are received in the grooves (136).

9. The method (200) according to claim 8, characterized in that: The method (200) further comprises: m) removing insulation (120) from ends of the plurality of electrical conductors (104) to expose portions of the plurality of electrical conductors (104); n) cutting notches (126) in the insulation (120) between the exposed portions (122) of the plurality of electrical conductors (104); and o) placing the ends of the plurality of rectangular protrusions (134) within the recesses (126).

10. An electrical connector (100), the electrical connector being produced by a process comprising the following steps: a) providing an insulated flexible flat cable (102) having a plurality of electrical conductors (104); b) inserting the flat cable (102) into a connector housing (114); c) inserting the flat cable (102) into a terminal housing (106); d) attaching a plurality of electrical terminals (110) to the plurality of electrical conductors (104); e) pulling the flat cable (102) to pull the plurality of electrical terminals (110) into a plurality of terminal cavities (108) defined in the terminal housing (106); and f) pulling the flat cable (102) to further pull the terminal housing (106) into the connector housing (114).

11. The electrical connector (100) according to claim 10, characterized in that: The plurality of electrical terminals (110) are formed from unfolded sheet metal, wherein the process further comprises: g) attaching the plurality of electrical terminals (110) to the plurality of electrical conductors (104).

12. The electrical connector (100) according to claim 11, characterized in that: The plurality of electrical conductors (104) have a substantially rectangular cross-section, wherein the process further comprises: h) removing insulation (120) from ends of the plurality of electrical conductors (104) to expose portions of the plurality of electrical conductors (104); and i) folding the plurality of electrical conductors (104) over edges (132) of the plurality of electrical terminals (110).

13. The electrical connector (100) according to claim 10, characterized in that: The terminal housing (106) includes a seal from the terminal housing (106) to the connector housing (114), wherein the process further comprises: j) inserting the flat cable (102) into a cable-to-terminal housing (106) seal (118); and k) pulling the flat cable (102) to draw the terminal housing (106) seal (118) into a sealed cavity defined in the terminal housing (102).

14. The electrical connector (100) according to claim 10, characterized in that: The process also includes: 1) Attaching a terminal cap (112) to the terminal housing (106).

15. The electrical connector (100) according to claim 14, characterized in that: The terminal cap (112) defines a plurality of rectangular protrusions (134) located between the plurality of electrical terminals (110), wherein the terminal housing (106) defines a plurality of grooves (136) located between the plurality of electrical terminals (110), and the plurality of rectangular protrusions (134) are received in the grooves (136).

16. The electrical connector (100) according to claim 15, characterized in that: The process also includes: m) removing insulation (120) from ends of the plurality of electrical conductors (104) to expose portions of the plurality of electrical conductors (104); n) cutting notches (126) in the insulation (120) between the exposed portions (122) of the plurality of electrical conductors (104); and o) placing the ends of the plurality of rectangular protrusions (134) within the recesses (126).

17. An electrical connector (100) assembly comprising: An insulated flexible flat cable (102) having a plurality of electrical conductors (104), wherein a portion of each of the plurality of electrical conductors (104) is exposed; a plurality of electrical terminals (110) formed from unfolded sheet metal and attached to the plurality of electrical conductors (104), wherein the plurality of electrical conductors (104) are folded over edges (132) of exposed portions (122) of the plurality of electrical conductors (106); a terminal housing (106) having a plurality of terminal cavities (108) in which the plurality of electrical terminals (110) are disposed; a terminal cap (112) attached to an end of the terminal housing (106); and A connector housing (114) in which the terminal housing (106) is disposed.

18. The electrical connector (100) assembly according to claim 17, characterized in that: The terminal cap (112) defines a plurality of rectangular protrusions (134) located between the plurality of electrical terminals (110), wherein the terminal housing (106) defines a plurality of grooves (136) located between the plurality of electrical terminals (110), and the plurality of rectangular protrusions (134) are received in the grooves (136).

19. The electrical connector (100) assembly according to claim 18, characterized in that: The flat cable (102) defines a recess (126) in the insulation (120) between the exposed portions (122) of the plurality of electrical conductors (104), and ends of the plurality of rectangular protrusions (134) are disposed within the recess (126).

20. The electrical connector (100) assembly according to claim 17, characterized in that: The plurality of electrical terminals (110) are selected from a list consisting of male blade terminals and female tuning fork terminals.

Images