Flat cable switching assembly, electric connection structure and flat cable manufacturing method

Abstract

The invention relates to the technical field of conductive connection, and particularly discloses a flat cable switching assembly, an electric connection structure and a flat cable manufacturing method, the flat cable switching assembly comprises an FFC (Flexible Flat Cable), and the end part of the FFC is provided with a plurality of contact pins which are arranged at intervals in a comb tooth shape; and the plurality of conversion terminals are arranged in one-to-one correspondence with the contact pins, and each conversion terminal is fixedly connected with the corresponding contact pin and is used for electrically connecting the corresponding contact pin to an outgoing line of the electronic device. According to the flat cable switching assembly, the electric connection structure and the flat cable manufacturing method provided by the invention, the problem that an electronic device with an outgoing line cannot be in butt joint with an FFC (Flexible Flat Cable) can be solved.

Description

Technical Field

[0001] This invention relates to the field of conductive connection technology, and in particular to a flat cable adapter assembly, an electrical connection structure, and a method for manufacturing a flat cable. Background Technology

[0002] In automotive electronic systems, electrical connectors are crucial components for signal transmission and power supply between electrical components. Currently, common electrical connectors mainly include two types: flexible flat cables (FFC) and insulated wires (consisting of a copper conductive core and an outer insulating sheath). Insulated wires, due to their longer development history and mature technology, are widely used in gasoline-powered vehicles, and the vast majority of electronic devices are interconnected via them. These electronic devices typically have their own insulated wires as leads, and the free ends of these leads generally have exposed conductive cores or are equipped with male / female connector plugs for electrical connection with other components.

[0003] With the rapid development of the new energy vehicle industry, electric vehicles have placed higher demands on energy density, lightweight design, and spatial layout. However, many electronic components in new energy vehicles are still interchangeable with those in traditional gasoline vehicles, and their lead-out wiring structures primarily use insulated wires. Due to the long distances of the vehicle's electrical wiring, continued extensive use of insulated wires would significantly increase vehicle weight and encroach on interior space, thus affecting the electric vehicle's range and overall energy efficiency. Therefore, insulated wire connection solutions are no longer sufficient to meet the market demand for high-efficiency, compact wiring in new energy vehicles.

[0004] On the other hand, FFC has advantages such as thinness, light weight, good flexibility, and small wiring space occupation, which better meet the requirements of new energy vehicles for high energy density and lightweight design. However, due to the inertia of the automotive electronics supply chain and product structure, most electronic devices on the market still mainly use self-insulated wires as leads, making it difficult to fully switch to designs with self-insulated FFC interfaces in the short term. This contradiction highlights the shortcomings of existing connection solutions during the transition period: they cannot fully utilize the advantages of FFC in weight reduction and space saving, and they are also difficult to directly support the interface standards of existing wire-type devices.

[0005] Therefore, existing electrical connection lines need to be improved to solve the problem that electronic devices with built-in leads cannot be connected to FFC cables.

[0006] The information disclosed in this background section is included only to enhance the understanding of the context of this disclosure, and therefore may contain information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0007] One objective of this invention is to provide a flat cable adapter assembly, an electrical connection structure, and a method for manufacturing a flat cable, which can solve the problem that electronic devices with built-in leads cannot be connected to FFC cables.

[0008] To achieve the above objectives, in one aspect, the present invention provides a flat cable adapter assembly, comprising: including:

[0009] The FFC cable has several contact pins arranged in a comb-like pattern at its end.

[0010] A plurality of adapter terminals are provided corresponding to each of the contact pins, and each adapter terminal is fixedly connected to the corresponding contact pin for electrically connecting the corresponding contact pin to the lead wire of the electronic device.

[0011] Optionally, the adapter terminal is a metal terminal, and the end of the metal terminal away from the contact foot is formed as a connector insertion part.

[0012] Optionally, the connector plug portion can be either a male or a female connector.

[0013] Optionally, the adapter terminal includes a metal terminal and a wire wrapped in insulation that is crimped or welded to the metal terminal.

[0014] Optionally, the metal terminal is crimped and fixed to the corresponding contact foot.

[0015] Optionally, the metal terminal is provided with:

[0016] A conductive body is disposed opposite to the corresponding contact pin;

[0017] A plurality of deformable plates, each of the deformable plates being fixed to both sides of the conductive body;

[0018] in,

[0019] The deformable plates on both sides of the conductive body are configured as follows:

[0020] In its initial flat state, it forms a U-shaped channel with the conductive body for the insertion of the contact pin;

[0021] Under pressure and bending, it deforms toward the conductive body to press the contact foot against the conductive body.

[0022] Optionally, the metal terminal is welded to the corresponding contact foot.

[0023] Optionally, the adapter terminal is a wire with a sheath, one end of which has an exposed conductive core that is soldered to the corresponding contact pin.

[0024] On the other hand, an electrical connection structure is provided, including any of the flat cable adapter components described above, and an electronic device with a plurality of leads.

[0025] Each of the lead wires is connected to each of the adapter terminals of the flat cable adapter assembly.

[0026] In another aspect, a method for manufacturing a flat cable is provided, for manufacturing any of the aforementioned flat cable adapter components, characterized in that it includes:

[0027] The adapter terminal is crimped or soldered to the corresponding contact pin.

[0028] The beneficial effects of this invention are as follows: It provides a flat cable adapter assembly, an electrical connection structure, and a method for manufacturing a flat cable. The FFC cable end has several contact pins arranged in a comb-like pattern, which forms the basis for achieving high-density electrical connections. Each adapter terminal and each contact pin are arranged in a one-to-one correspondence and form a stable electrical path through a fixed connection.

[0029] The core function of this adapter terminal is to act as a bridge between a physical interface and electrical signals. One end reliably connects to the exposed contacts of the FFC cable, while the other end is configured as a lead wire for connecting electronic devices. This structural design fundamentally solves the problem that FFC cables cannot reliably interface with conventional insulated wire leads. It not only fully utilizes the advantages of FFC cables—lightweight, thin, and flexible—to optimize the main wiring harness, but also achieves backward compatibility with a large number of existing electronic devices that use insulated wires as leads through the ingenious structure of the adapter terminal. This allows new energy vehicles to achieve weight reduction and space saving at the wiring harness level without replacing existing electronic components.

[0030] Therefore, the flat cable adapter assembly, electrical connection structure, and flat cable manufacturing method provided by this invention can solve the problem that electronic devices with their own leads cannot be connected to FFC cables. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 A schematic diagram of the structure of the flat cable adapter assembly provided in the embodiment;

[0033] Figure 2This is a schematic diagram of the flat cable adapter assembly in Scheme 1;

[0034] Figure 3 This is a schematic diagram of the flat cable adapter assembly in Scheme 2;

[0035] Figure 4 This is a schematic diagram of the flat cable adapter assembly in Scheme 3.

[0036] In the picture:

[0037] 1. FFC cable; 101. Contact pin;

[0038] 2. Adapter terminals;

[0039] 201. Metal terminal; 2011. Conductive body; 2012. Deformable pressure plate; 2013. Connector insertion part; 2014. U-shaped channel;

[0040] 202. Insulated conductor; 2021. Conductive core wire. Detailed Implementation

[0041] In this invention, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment can be included in at least one embodiment of the invention. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this invention, as long as there is no technical contradiction or conflict, the technical features mentioned in each embodiment can be combined in any way to form a corresponding implementable technical solution.

[0042] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit the invention.

[0043] In the description of this invention, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " generally indicates that the preceding and following objects have an "or" logical relationship.

[0044] In this invention, terms such as “first” and “second” are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy, or order between these entities or operations.

[0045] Without further limitations, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this invention is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0046] Similar to the understanding in the Examination Guidelines, in this invention, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments of this invention, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0047] In the description of the embodiments of the present invention, the spatial related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of the present invention or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0048] Unless otherwise explicitly stated or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this invention, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral arrangement; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this invention according to the specific circumstances.

[0049] This invention provides a flat cable adapter assembly, an electrical connection structure, and a method for manufacturing a flat cable, which can solve the problem that electronic devices with their own leads cannot be connected to FFC cables.

[0050] Example 1

[0051] This embodiment provides an electrical connection structure, which includes a flat cable adapter assembly and an electronic device with several leads.

[0052] It should be noted that the "electronic devices" described in this invention have broad applicability, particularly referring to functional units in fields such as automobiles, industrial control, and consumer electronics that require signal transmission or power supply via insulated wires. Specifically, these can be sensors (such as temperature and position sensors), actuators (such as solenoid valves and small motors), control modules (such as sub-modules of an ECU), displays, or various switches. These devices typically have built-in leads as standard electrical interfaces. The core value of this adapter assembly lies in its ability to connect these existing devices via FFC cables without altering their original structure, thereby fully leveraging the advantages of FFC.

[0053] See Figure 1 The flat cable adapter assembly includes:

[0054] FFC cable 1, wherein the end of the FFC cable 1 is provided with a plurality of contact pins 101 arranged in a comb-like space;

[0055] A plurality of adapter terminals 2 are provided corresponding to each of the contact pins 101. Each adapter terminal 2 is fixedly connected to the corresponding contact pin 101 and is used to electrically connect the corresponding contact pin 101 to the lead wire of the electronic device. Optionally, each lead wire is mated with each adapter terminal 2 of the flat cable adapter assembly.

[0056] The flat cable adapter assembly provided in this embodiment comprises an FFC cable 1 and several adapter terminals 2. The FFC cable 1 has several contact pins 101 arranged in a comb-like pattern at its end, which form the basis for achieving high-density electrical connections. Each adapter terminal 2 and each contact pin 101 are configured in a one-to-one correspondence and are fixedly connected to form a stable electrical path.

[0057] The core function of the adapter terminal 2 is to act as a bridge between a physical interface and electrical signals. One end reliably connects to the exposed contact pin 101 of the FFC cable 1, while the other end is configured as a lead wire for connecting electronic devices. This structural design fundamentally solves the problem that the FFC cable 1 cannot reliably connect to conventional insulated wire leads. It not only fully utilizes the advantages of the FFC cable 1—lightweight, thin, and flexible—to optimize the main wiring harness, but also achieves backward compatibility with a large number of existing electronic devices that use insulated wires as leads through the ingenious structure of the adapter terminal 2. This allows new energy vehicles to achieve weight reduction and space saving at the wiring harness level without replacing existing electronic devices.

[0058] Therefore, the flat cable adapter assembly and electrical connection structure provided by the present invention can solve the problem that electronic devices with their own leads cannot be connected to the FFC cable 1.

[0059] Depending on the actual application scenario, this embodiment provides three optional implementation methods for the specific structure of the adapter terminal 2.

[0060] Option 1: Adapter terminal 2 is a metal terminal 201 used for mating and unmating with the connector.

[0061] See Figure 2 When a female or male connector is connected to the lead wire, the adapter terminal 2 is a metal terminal 201, and the end of the metal terminal 201 away from the contact foot 101 is formed into a connector insertion part 2013.

[0062] Pre-forming the terminals into connector insertion parts 2013 means that this flat cable adapter assembly can be directly used with standardized connectors. During operation, when connecting electronic devices, simply insert the connector (male or female matching the connector insertion part 2013) with the device's lead-out end, greatly simplifying on-site installation. This implementation improves connection standardization and assembly efficiency, avoids tedious on-site wiring, and provides better anti-misfit and locking functions for the connector interface, enhancing connection reliability.

[0063] Specifically, the connector insertion part 2013 is either a male (for mating with a female connector on the lead-out line) or a female (for mating with a male connector on the lead-out line). For example, when the lead-out line of the electronic device has a female connector at the end, the connector insertion part 2013 is preferably formed as a male pin structure to achieve smooth mating; conversely, if the lead-out line has a male pin at the end, the connector insertion part 2013 should be formed as a matching female interface structure. This flexible design allows the flat cable adapter assembly to adapt to interface standards of different polarities, enhancing its versatility and applicability. Its beneficial effect is that it provides specific and optional interface implementation schemes, covering mainstream connector types on the market, ensuring that this adapter assembly has good compatibility.

[0064] Option 2: Adapter terminal 2 uses insulated wire 202 as the external interface.

[0065] See Figure 3 When the end of the lead wire is provided with a terminal block or a power clamp or other adapter that directly connects to the conductive core wire 2021, the adapter terminal 2 includes a metal terminal 201 and a wire 202 that is crimped or welded to the metal terminal 201.

[0066] This results in the entire flat cable adapter assembly extending a section of insulated wire 202 at the output end. During operation, this pre-fixed insulated wire 202 can be reliably connected to the leads of electronic devices via soldering, crimping, or the use of terminal blocks. This implementation is particularly suitable for scenarios where interfaces are non-standardized or where space is limited and standard connectors cannot be used. It provides extremely high connection flexibility, capable of handling various non-standard and customized connection requirements, while crimping or soldering ensures the mechanical strength and electrical continuity of the connection points.

[0067] Option 3: Adapter terminal 2 is a 202 insulated wire.

[0068] See Figure 4 When the end of the lead wire is equipped with a terminal block or a clamp for direct connection to the conductive core wire 2021, the insulated wire 202 can also be used directly as the adapter terminal 2. Specifically, the conductive core wire 2021 at one end of the insulated wire 202 is exposed and soldered to the corresponding contact pin 101.

[0069] In this solution, the insulation sheath of one end of a wrapped wire 202 is removed, exposing the conductive core 2021. This exposed conductive core 2021 is then directly soldered to the corresponding contact pin 101 of the FFC cable 1 for a fixed connection. Thus, each wrapped wire 202 simultaneously serves as both an adapter terminal 2 and the final lead-out wire. Its working logic is very straightforward: one end of the wrapped wire 202 is soldered to the FFC during prefabrication; during on-site installation, only the connection of the other end of the wrapped wire 202 to the electronic device needs to be addressed. This implementation simplifies the structure to the maximum extent, eliminating the need for a separate metal terminal 201, reducing material costs and assembly complexity, and is ideal for applications with a limited number of cables and strictly limited structural space.

[0070] As an optional implementation, in Scheme 1 and Scheme 2 above, the metal terminal 201 is crimped and fixed to the corresponding contact foot 101. Crimping is a mature technology that uses mechanical pressure to plastically deform the metal terminal 201, thereby tightly fitting it to the contact foot 101 to form a reliable electrical connection. In specific operation, a dedicated crimping tool is used to apply pressure to the metal terminal 201, causing it to undergo permanent deformation, thus wrapping and pressing it tightly onto the surface of the contact foot 101. This fixing method does not involve high-temperature processes, avoiding the risk of heat damage that may occur with welding, and is particularly suitable for materials with limited heat resistance such as FFC; at the same time, crimped connections have the advantages of high consistency, quick operation, low connection resistance, and good stability, making them very suitable for automated mass production.

[0071] Specifically, the metal terminal 201 is provided with:

[0072] A conductive body 2011 is disposed opposite to the corresponding contact pin 101;

[0073] A plurality of deformable sheets 2012 are fixed to both sides of the conductive body 2011;

[0074] in,

[0075] The deformable pressure plates 2012 on both sides of the conductive body 2011 are configured as follows:

[0076] In its initial flat state, it together with the conductive body 2011 forms a U-shaped channel 2014 for the insertion of the contact foot 101;

[0077] Under pressure and bending, it deforms toward the conductive body 2011 to cooperate with the conductive body 2011 to press the contact foot 101.

[0078] The conductive body 2011, serving as the primary current path carrier, is positioned directly opposite the corresponding contact pin 101. The deformable pressure plates 2012 fixed to both sides of the conductive body 2011 are key moving components for achieving the crimping function. Their collaborative operation is divided into two distinct timing phases:

[0079] In the first stage, i.e. the initial flat state, the deformable pressure plates 2012 on both sides and the conductive body 2011 together form a U-shaped channel 2014 with a guiding function, which allows the contact pin 101 at the end of the FFC cable 1 to be easily and accurately inserted into the predetermined position.

[0080] In the second stage, when the external pressing tool applies pressure to the deformable pressing plate 2012, each deformable pressing plate 2012 changes from a straight state to a bent state. They undergo plastic deformation towards the conductive body 2011 in the center, like jaws, thereby forming a three-sided clamping of the contact foot 101 inserted therein together with the conductive body 2011 from both sides, generating huge contact pressure.

[0081] This design achieves a complete process of precise guidance, rapid insertion, and secure crimping of the contact foot 101 through a simple mechanical structure, ensuring the repeatability and consistency of the crimping process. At the same time, the multi-point clamping force results in a large electrical connection area, low contact resistance, and high mechanical tensile strength, which greatly improves the reliability of the connection.

[0082] In some other embodiments, the metal terminal 201 can also be welded to the corresponding contact foot 101. Welding, for example using soldering or laser welding, involves forming an alloy layer at the junction of the terminal and contact foot 101 using molten solder, thereby achieving mechanical interlocking and electrical conductivity. This fixing method can form a metallurgical bond at the molecular level, typically achieving lower contact resistance and higher connection strength than physical crimping. It also provides good airtightness, effectively prevents oxidation, and is suitable for applications with extremely high requirements for connection resistance and long-term stability.

[0083] In summary, the flat cable adapter assembly and electrical connection structure provided in this embodiment have the following advantages:

[0084] ① By setting up adapter terminals 2 that correspond one-to-one with the contact pins 101 of the FFC cable 1, a standard electrical conversion interface is constructed, which effectively solves the problem that electronic devices with their own leads cannot be reliably connected to the FFC cable 1 directly;

[0085] ② By designing one end of the adapter terminal 2 as a connector insertion part 2013 (male pin or female interface), a standardized mating interface is provided, which significantly improves assembly efficiency and the convenience and reliability of connection.

[0086] ③ By designing the other end of the adapter terminal 2 to be crimped or welded to fix the sheathed wire 202, a flexible non-standard connection solution is provided, enhancing the adaptability to different application scenarios;

[0087] ④ By adopting a metal terminal 201 structure with a conductive body 2011 and a deformable pressure plate 2012, the guiding insertion and multi-face pressing of the contact foot 101 are realized, ensuring the consistency of the crimping process and the mechanical strength and electrical performance of the connection point.

[0088] ⑤ By constructing an electrical connection structure that includes flat cable adapter components and electronic devices, the lightweight advantages of FFC and the efficient compatibility with traditional wire interface devices are achieved, providing support for system-level weight reduction and space optimization.

[0089] Example 2

[0090] This embodiment provides a method for manufacturing a flat cable, which is used to manufacture any of the flat cable adapter components described in Embodiment 1, and has the same function and beneficial effects.

[0091] The flat cable manufacturing method provided in this embodiment includes the following steps:

[0092] The adapter terminal is crimped or soldered to the corresponding contact pin.

[0093] Understandably, whether using precision-structured metal terminals for crimping or simple welding for fixing, this manufacturing method defines an efficient and reliable production process. It provides a clear and industrially feasible manufacturing solution. By choosing between crimping or welding, two mature processes, it can adapt to production needs with different performance requirements and cost budgets, ensuring the consistency and reliability of the final product (flat cable adapter assembly).

[0094] It should be noted that, based on Embodiment 1, features not explained in this embodiment will be explained using the methods described in Embodiment 1, and will not be repeated here.

[0095] Finally, it should be noted that although the above embodiments have been described in the description and drawings of this invention, this should not limit the scope of patent protection of this invention. Any technical solutions that are based on the essential concept of this invention, utilize the content described in the description and drawings of this invention to make equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this invention.

Claims

1. A flat cable adapter assembly, characterized in that, include: FFC cable (1), the end of the FFC cable (1) is provided with a plurality of contact pins (101) arranged in a comb-like pattern. A plurality of adapter terminals (2) are provided in a one-to-one correspondence with each of the contact pins (101), and each adapter terminal (2) is fixedly connected to the corresponding contact pin (101) for electrically connecting the corresponding contact pin (101) to the lead wire of the electronic device.

2. The flat cable adapter assembly according to claim 1, characterized in that, The adapter terminal (2) is a metal terminal (201), and the end of the metal terminal (201) away from the contact foot (101) is formed into a connector plug part (2013).

3. The flat cable adapter assembly according to claim 2, characterized in that, The connector plug (2013) is either a male or a female connector.

4. The flat cable adapter assembly according to claim 1, characterized in that, The adapter terminal (2) includes a metal terminal (201) and a sheathed wire (202) that is crimped or welded to the metal terminal (201).

5. The flat cable adapter assembly according to any one of claims 2-4, characterized in that, The metal terminal (201) is pressed and fixed to the corresponding contact foot (101).

6. The flat cable adapter assembly according to claim 5, characterized in that, The metal terminal (201) is provided with: A conductive body (2011) is disposed opposite to the corresponding contact foot (101); A plurality of deformable pressure plates (2012), each of the deformable pressure plates (2012) being fixed to both sides of the conductive body (2011); in, The deformable plates (2012) on both sides of the conductive body (2011) are configured as follows: In its initial flat state, it together with the conductive body (2011) forms a U-shaped channel (2014) for the insertion of the contact foot (101). In a bent state under pressure, it deforms toward the conductive body (2011) to cooperate with the conductive body (2011) to press the contact foot (101).

7. The flat cable adapter assembly according to any one of claims 2-4, characterized in that, The metal terminal (201) is welded and fixed to the corresponding contact foot (101).

8. The flat cable adapter assembly according to claim 2, characterized in that, The adapter terminal (2) is a wire wrapped with a protective sheath (202). The conductive core wire (2021) at one end of the wire wrapped with a protective sheath (202) is exposed and welded to the corresponding contact foot (101).

9. An electrical connection structure, characterized in that, Includes the flat cable adapter assembly as described in any one of claims 1-8, and an electronic device with a plurality of leads; Each of the lead wires is connected to each of the adapter terminals (2) of the flat cable adapter assembly.

10. A method for manufacturing a flat cable, used to manufacture the flat cable adapter assembly according to any one of claims 1-8, characterized in that, include: The adapter terminal (2) is crimped or soldered to the corresponding contact foot (101).

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