Standardized ffc / fpc high voltage cable assembly system

Abstract

A cable assembly includes a flexible flat cable (FFC) (10), an inner housing (50), and an outer housing (82). The outer housing (82) defines an inner cavity (86) and a first cable opening (88) in communication with the inner cavity (86) and adapted to receive the FFC (10) in an insertion direction. The inner housing (50) is selectively securable to the outer housing (82) at least partially within the inner cavity (86), and the inner housing (50) includes a plurality of terminal openings (54) and a second cable opening (56) aligned with the first cable opening (88) of the outer housing (82) and receiving a free end of the FFC (10). The plurality of terminal openings (54) has a plurality of conductive terminals (30) disposed therein, each terminal (30) having a first end adapted to engage a corresponding mating terminal of a mating connector and a second end conductively connected to one of a plurality of exposed conductors (12) of the FFC (10).

Description

Technical Field

[0001] This disclosure relates to electrical connectors, and more specifically, to connector assemblies suitable for use with flat, flexible cables in high-voltage electrical connection systems. Background Technology

[0002] Flexible flat cable (FFC) or flexible printed cable (FPC) is an electrical component consisting of at least one conductor (e.g., a metal foil conductor) embedded within a thin, flexible insulating strip. Flat flexible cables are gaining popularity in many industries due to their advantages over their traditional "round wire" counterparts. Specifically, in addition to having a lower profile and lighter weight, FFCs make it easier to implement large circuit paths and utilize significantly less space or volume compared to round wire-based architectures. Therefore, FFCs are implemented in many complex and / or high-capacity applications, including wire harnesses used in automotive / electric vehicle manufacturing.

[0003] In electric vehicles, there is a trend towards minimizing copper weight by increasing system voltage to reduce current and the size of the wires required to carry that current. Consequently, 48V electrical systems are becoming increasingly popular. Given the complexity of these applications, there is a corresponding need to develop standardized connector systems for 48V electrical systems, which will reduce the number of connector types used in vehicles. Combining FFC with 48V systems offers many advantages, including reduced connector housing size, system weight, and overall complexity. However, implementing FFC in high-voltage systems is not without its challenges. The required considerations include the increased challenges associated with sealing the FFC, providing sufficient strain relief, and achieving the conductor gaps required for high-voltage applications.

[0004] Therefore, there is a need for a connector system suitable for use with FFC in high-pressure environments, which would facilitate automated manufacturing and component standardization. Summary of the Invention

[0005] In one embodiment of this disclosure, the cable assembly includes a flexible flat cable (FFC), an inner housing, and an outer housing. The outer housing defines an inner cavity and a first cable opening communicating with the inner cavity and adapted to receive the FFC in an insertion direction. The inner housing is selectively secured to the outer housing, at least partially within the inner cavity, and includes a plurality of terminal openings and a second cable opening aligned with the first cable opening of the outer housing to receive a free end of the FFC. A plurality of conductive terminals are arranged in the plurality of terminal openings, each terminal having a first end adapted to engage with a corresponding mating terminal of a mating connector and a second end conductively connected to one of a plurality of exposed conductors of the FFC. Attached Figure Description

[0006] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 This is a top (or bottom) perspective view of an exemplary FFC used to describe a connector system according to embodiments of the present disclosure;

[0008] Figure 2 It was cut along section AA. Figure 1 A cross-sectional view of the FFC;

[0009] Figure 3 This is a top perspective view of the FFC and reinforcing element according to an embodiment of the present disclosure;

[0010] Figure 4 yes Figure 3 A bottom-view perspective of the FFC and reinforcing elements;

[0011] Figure 5 This is a side perspective view of a terminal used in a connector, plug, and / or cable assembly according to an embodiment of the present disclosure;

[0012] Figure 6 yes Figure 5 Side view of the terminal;

[0013] Figure 7 This is a front perspective view of a cable subassembly including an FFC, a reinforcing element, and multiple terminals according to an embodiment of the present disclosure;

[0014] Figure 8 This is a front perspective view of the inner housing of a connector system according to an embodiment of the present disclosure;

[0015] Figure 9 It was cut along section BB. Figure 8 A cross-sectional view of the inner shell;

[0016] Figure 10 This is a rear perspective view of the housing of a connector system according to an embodiment of the present disclosure;

[0017] Figure 11 yes Figure 10 A front-view perspective view of the outer casing;

[0018] Figure 12 This is an exploded side perspective view of a connector system according to an embodiment of the present invention;

[0019] Figure 13 It was cut along section CC. Figure 12 A cross-sectional view of the system;

[0020] Figure 14 It is in the assembly state. Figure 12 and Figure 13A front perspective view of the connector assembly; and

[0021] Figure 15 yes Figure 14 Rear-view perspective of the connector system. Detailed Implementation

[0022] Exemplary embodiments of this disclosure will be described in detail below with reference to the accompanying drawings, wherein like reference numerals denote like elements. However, this disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concepts of this disclosure to those skilled in the art.

[0023] In the following detailed description, numerous specific details are set forth for purposes of explanation in order to provide a thorough understanding of the disclosed embodiments. However, it will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and apparatuses are schematically illustrated for the purpose of simplifying the drawings.

[0024] According to one embodiment of this disclosure, a cable assembly includes an FFC, an inner housing, and an outer housing. The outer housing defines an inner cavity and a first cable opening communicating with the inner cavity and adapted to receive the FFC in an insertion direction. The inner housing is selectively secured to the outer housing, at least partially within the inner cavity, and includes a plurality of terminal openings and a second cable opening aligned with the first cable opening of the outer housing to receive a free end of the FFC. A plurality of conductive terminals are arranged in the plurality of terminal openings, each terminal having a first end adapted to engage with a corresponding mating terminal of a mating connector and a second end conductively connected to one of a plurality of exposed conductors of the FFC. A seal is formed between the FFC and the first cable opening and between the outer housing and a mating connector or head (not shown).

[0025] According to another embodiment of this disclosure, a connector for an FFC includes a housing having a first cable opening formed through the housing and adapted to receive an FFC in an insertion direction. The connector also includes an inner housing having a plurality of terminal openings adapted to receive a plurality of conductive terminals, and a second cable opening communicating with the plurality of terminal openings. The second cable opening is adapted to receive the free end of the FFC inserted through the first cable opening of the housing. The inner housing is selectively fixed to the housing such that the first and second cable openings are aligned in the insertion direction.

[0026] In another embodiment of this disclosure, a method of manufacturing an FFC system includes the following steps: 1) arranging a plurality of conductive terminals within an inner connector housing, wherein each terminal defines a soldering / brazing area suitable for electrical connection to a conductor of the FFC; 2) inserting a free end of the FFC along a first direction through a cable opening in an outer connector housing; 3) inserting the free end of the FFC into the inner connector housing such that a plurality of conductors of the FFC are aligned with corresponding terminals of a plurality of terminals; 4) soldering / brazing the plurality of conductors to the plurality of terminals; 5) after the conductors are joined to the terminals, inserting the inner connector housing into the outer connector housing; and 6) mechanically securing the inner connector housing to the outer connector housing.

[0027] Now refer to Figure 1 and Figure 2 An exemplary FFC 10 for describing embodiments of the present disclosure is shown. The FFC 10 includes one or more conductors 12 embedded within an insulating material 14. The conductors 12 may include sheets or foils, such as copper foil, patterned in any desired configuration only as an example. In an exemplary embodiment, the conductors 12 include linear or longitudinally extending conductive traces or paths. The insulating material 14, such as a polymeric insulating material, may be applied to either side of the conductors 12 by an adhesive (laminated structure) or extrusion to create an embedded conductor arrangement. The insulating material 14 may be selectively removed or initially not applied to expose the conductors 12 in desired areas—such as in windows 16 defined on the top and / or bottom sides of the exemplary FFC 10. In an exemplary embodiment, windows 16 may be formed on the top and bottom sides of the FFC 10 such that the conductors 12 are exposed alternately on each side of the FFC 10 across its width, as shown below. Figure 2 As shown in the cross-sectional view. As will be described in more detail herein, the exposed portion of each conductor 12 is adapted to be connected (e.g., brazed or soldered) to the corresponding conductive terminal. Forming windows on each side of the FFC 10 allows for electrical connection of the terminals to both sides of the FFC 10 (i.e., the top and bottom sides), which can increase connector density and / or reduce the size of the connector housing. Still referring to Figure 1 and Figure 2 The slot or serration 17 may be formed through the insulating material 14, particularly on the free end 11 of the FFC 10 and / or in the region between the conductors 12 in the free end 11. The slot 17 may correspond to a protruding feature within the plug or housing, which is used to position the FFC 10 in the protruding feature during manufacturing and / or to maintain the creepage and clearance requirements of the cable.

[0028] Now refer to Figure 3 and Figure 4In another embodiment, the FFC 10 may be fitted with a reinforcing element or reinforcement 20 to form a cable subassembly. Specifically, the reinforcing element 20 may comprise a generally planar rectangular element, which may be formed of an insulating polymer material. The free ends of the exemplary FFC 10 are wound around the reinforcing element 20 (e.g., folded over the reinforcing element 20 at approximately 180 degrees) and may be bonded to the reinforcing element 20 via, for example, an adhesive hot melt adhesive. As shown, the illustrative FFC 10, after folding, has a total of nine conductors 12 exposed by windows 16 on each of the illustrated top and bottom sides, wherein the free ends of the FFC define a serrated or sawtooth configuration of slots 17. Figure 1 and Figure 2 Unlike the FFC 10, in this embodiment, the window 16 is formed only on one side of the FFC 10 before folding around the reinforcing element 20, thus simplifying the manufacturing process of the FFC. Using the reinforcing element 20 integrated into the FFC 10 has several advantages. For example, it allows for precise positioning of the FFC within a larger plug or connector, facilitating accurate alignment with associated terminals, and improving the mechanical stability and strain relief of the FFC.

[0029] Figure 7 An exemplary subassembly 40 is shown, comprising nine conductor FFCs 10, reinforcing elements 20, and multiple terminals 30. As shown, after folding, the exposed conductors 12 on each side of the reinforcing elements 20 (five and four conductors respectively) can be brazed or soldered to the terminals 30 before or after insertion into the exemplary connector housing. The staggering of the top and bottom terminals 30 relative to each other in the vertical direction is determined by the lateral spacing of the nine conductors 12 on the FFCs 10. The staggered terminals in this folded FFC arrangement enable greater terminal / conductor density and improved encapsulation efficiency. As an example, the nine conductors of a single FFC 10 can originate from the joints of multiple discrete downstream FFCs of the cable assembly. More specifically, five-conductor FFCs and four-conductor FFCs can be joined to form a composition of nine conductor FFCs 10.

[0030] exist Figure 5 and Figure 6 The diagram shows a detailed view of an exemplary conductive terminal 30 according to an embodiment of the present disclosure. The exemplary terminal 30 has a body 32 that defines a concave mating end or opening 34, which is adapted to receive, for example, a conductive convex mating terminal (e.g., a pin terminal).

[0031] The solder end 36 of terminal 30 defines a soldering area or surface 37 on its underside, which is adapted to be electrically connected to the exposed conductor 12 of FFC 10 via soldering or brazing. As shown, the free end 38 of solder end 36 is inclined away from soldering surface 37, or radially upward in the indicated orientation. The inclined free end 38 allows FFC 10 to be more easily inserted into the connector where terminal 30 is arranged without the risk of damaging conductor 12, as will be explained below.

[0032] In the exemplary terminal 30, the solder end 36 is offset from the remainder of the terminal body 32 via a drop section 35 (i.e., in a direction perpendicular to the mating direction of the terminal). The drop section 35 includes two approximately 90-degree bends formed in the solder end 36 to define a generally Z-shaped or stepped profile. As can be seen from the figures, the terminal 30 can be formed by a combination of sheet metal forming operations, such as stamping and bending. Additional stamping can be used to shape the solder end 36 into a sufficiently wide and uniformly flat surface optimized for brazing to FFC. The solder end 36, particularly the solder area 37, can be tin-plated with solder, with flux applied to it before it is mounted into a connector or plug. Figure 3 and Figure 4 In this embodiment, the descent 35 will be omitted, and the welding area 37 will be aligned with the carrier cutting area 33.

[0033] Terminal 30 is adapted for mounting in a connector or plug assembly. Specifically, refer to... Figure 8 and Figure 9 The diagram illustrates an inner housing 50 of a connector according to an embodiment of the present disclosure. The inner housing 50 includes a body 52 (e.g., an insulating polymer body) defining a plurality of terminal openings 54. The terminal openings 54 are adapted to receive the aforementioned terminals 30 (e.g., such as…). Figure 9 (Seen from the rear). Terminals 30 can be pre-loaded into the inner housing 50 to define the inner housing assembly 60. It should be understood that, advantageously, the inner housing assembly 60 can be manufactured / assembled prior to final integration into a given cable system, as will be described in more detail herein.

[0034] The body 52 of the inner housing 50 also defines a cable trough or opening 56. The cable trough 56 extends to the rear of the body and communicates with each terminal opening 54. The cable trough 56 is adapted to receive the FFC 10 in an indicated direction (i.e., from the open rear side of the FFC 10 toward the front of the inner housing 50) or as... Figure 3 and Figure 4 The FFC and reinforcing element 20 sub-assemblies are shown in the figure.

[0035] The body 52 of the inner housing 50 also defines an inner seal retainer 58 (e.g., a retaining protrusion or lip) generally surrounding the body. The inner seal retainer 58 is adapted to engage with an inner seal of the housing assembly 80, such as... Figure 10-14 As shown. The inner housing 50 also defines a longitudinally extending slot 53 on each of its top and bottom sides. The slot 53 is adapted to engage with or receive a corresponding feature of the outer housing assembly 80. Specifically, a snap 55 may be formed in each slot 53, which is adapted to engage with a latch of the outer housing assembly 80, such as... Figure 10-14 As shown, it is used to selectively fasten or secure the inner housing 50 to the outer housing assembly 80.

[0036] For details, please refer to the following: Figure 9 In a cross-sectional view, in some embodiments, each terminal 30 can be directly secured to the body 52 within a corresponding terminal opening 54. This can be achieved through a frictional engagement of the terminal 30 and / or the inner housing 50 and / or an integral locking / latch feature. However, in the illustrated embodiment, a locking shank or insert 70 (e.g., a stainless steel locking insert) can be installed into each terminal opening 54 before the terminal 30 is loaded into the inner housing 50. The shank 70 includes a latch 72 that engages with a slot or opening in the body 52 for securing the shank within the terminal opening 54. The shank 70 also defines a locking protrusion 74. The locking protrusion 74 engages with a complementary locking feature 39 of the terminal 30 for securing the terminal 30 to the shank upon insertion, thereby holding and positioning the terminal within the terminal opening 54.

[0037] Still referencing Figure 9 With the terminal 30 installed in the terminal opening 54, the solder end 36 of the terminal extends into or communicates with the cable opening 56, such that the solder surface 37 of each terminal 30 is positioned in the cable opening. In this way, the solder surface 37 of each terminal 30 is exposed within the cable opening 56, such that after the FFC is inserted into the inner housing 50, the solder surface 37 is opposite and in contact with the corresponding exposed conductor 12 of the FFC 10. After the FFC 10 is inserted into the inner housing 50, each terminal of the terminal 30 can be brazed or soldered to a corresponding conductor in the conductor.

[0038] It should be understood that, although in Figure 9 Only a single terminal 30 is shown, but additional terminals will be arranged in each of the shown terminal openings 54, with the bottom row of terminals oriented as shown and the top row of terminals oriented in the opposite direction, such that their solder surfaces face downwards or opposite to the solder surface 37 of the shown bottom or lower terminal 30. In this way, the terminal 30 can be soldered to each of the top and bottom sides of the unfolded single extruded FFC 10 inserted into the cable opening 56, or soldered to... Figure 3, Figure 4 and Figure 11 The same side of the folded FFC 10 shown (although facing relatively).

[0039] Figure 10 and Figure 11 A housing assembly 80 of a connector or connector assembly according to an embodiment of the present disclosure is shown in more detail. Typically, the housing assembly 80 includes a housing or body 82 (e.g., a molded polymer body). The body 82 has an outer peripheral wall 94 and an inner peripheral wall 96. The inner peripheral wall 96 defines an inner housing receiving space 86 in which the inner housing 50 is adapted to be securely received. Specifically, the inner peripheral wall 96 of the body 82 defines a latch or latch arm 83 on its top and bottom sides. The latch arm 83 is adapted to engage with the inner housing 50, such as... Figure 14 As shown. More specifically, in one embodiment, each latch arm 83 defines a receiving slot 85 adapted to engage with a snap 55 of the inner housing 50.

[0040] The body 82 of the housing assembly 80 further defines a cable opening 88, into which the FFC 10 is adapted to be received and through. The cable opening 88 communicates with the inner housing receiving space 86. A cable seal or outer seal 92 (e.g., a rubber or polymer sealing ring) is fitted within the cable opening 88 and adapted to form a seal with the FFC 10 when it is inserted through the cable opening 88.

[0041] like Figure 11 As shown, the inner seal 90 is also disposed around the inner peripheral wall 96 and extends into an annular or circumferential opening or mating connector space defined between the inner and outer peripheral walls 94. The inner seal 90 is adapted to abut the inner housing 50 and specifically abut the inner seal retainer 58. Figure 11 As can be seen, the radially outward-facing ribbed side of the inner seal 90 is adapted to sealably engage with the radially inward-facing sealing surface of a mating connector (not shown) received between the inner wall 96 and the outer peripheral wall 94. As will be further understood by those skilled in the art, the mating connector can be secured to the housing assembly 80 via the latching connection shown and the associated connector position guarantee (CPA) device 84.

[0042] Connectors or connector assemblies / systems according to embodiments of this disclosure Figure 12-15 As shown in the image. (Refer to...) Figure 12 and Figure 13The unassembled view shows a connector system or connector assembly 100 according to an embodiment of the present disclosure, including a pre-assembled inner housing assembly 60, a pre-assembled outer housing assembly 80, and an FFC 10. During the final assembly of the connector assembly 100, the FFC 10 (with or without the reinforcing element 20) is inserted through a cable opening 88 in the body 82 of the outer housing assembly 80 and into a cable groove or opening 56 in the inner housing 50. Once fully inserted, the exposed conductors 12 of the FFC 10 align with and abut against each of the solder surfaces 37 of the terminals 30. At the illustrated joint 102 (see...), Figure 13 Terminal 30 is brazed or soldered to the corresponding conductor in conductor 12 of FFC 10 within the inner housing 50 using, for example, brazing or soldering.

[0043] Now refer to Figure 14 and Figure 15 In the assembly view of system 100, once the terminal 30 has been secured (e.g., soldered) to the FFC 10, the inner housing assembly 60 is inserted into the body 82 of the outer housing assembly 80 in a direction substantially opposite to the insertion direction of the FFC 10 into the outer housing assembly 80, and the inner housing assembly 60 is securely connected to the outer housing assembly 80. More specifically, the locking latch 83 of the body 82 extends into the slot 53 of the inner housing 50 until the recess 85 receives the snap-fit ​​55, thereby snapping the inner housing assembly 60 into the outer housing assembly 80, as shown. Figure 14 As shown. In this position, the inner seal 90 of the housing assembly 80 abuts against the inner seal retainer 58 of the inner housing 50 around its periphery in the direction in which the inner housing is inserted into the housing. The shown sealing rib of the inner seal 90 extends radially outward and into the receiving space of the mating connector, as described above, to form a seal with it when the system 100 is mated or inserted into the mating connector.

[0044] With the inner housing assembly 60 mating with the outer housing assembly 80, the outer seal 92 is subsequently heated to bond at the joint 99 to the insulating material or sheath 14 of the FFC 10, such as Figure 15 As shown in the diagram. This forms a waterproof seal between the FFC 10 and the interior of the connector assembly 100. Furthermore, combining the outer seal 92 with the FFC 10 provides mechanical strain relief for the assembly, thereby preventing the FFC 10 from being pulled out and / or disconnected from the terminal 30.

[0045] Those skilled in the art should understand that the above embodiments are intended to illustrate rather than limit. For example, those skilled in the art can make many modifications to the above embodiments, and the various features described in different embodiments can be freely combined with each other without conflicting in configuration or principle.

[0046] Although several exemplary embodiments have been shown and described, those skilled in the art will understand that various changes or modifications may be made to these embodiments without departing from the principles and spirit of this disclosure, the scope of which is defined in the claims and their equivalents.

Claims

1. A connector for flexible flat cables (FFC), comprising: The housing (82) has a first cable opening (88) formed through the housing (82) and adapted to receive the FFC (10) in the insertion direction. as well as Inner shell (50), comprising: Multiple terminal openings (54) are adapted to receive multiple conductive terminals (30); as well as The second cable opening (56), which communicates with the plurality of terminal openings (54) and is adapted to receive the free end of the insertion of the FFC (10) through the first cable opening (88) of the housing (82), wherein the inner housing (50) is selectively fixed to the housing (82) such that the first cable opening (88) and the second cable opening (56) are aligned in the insertion direction.

2. The connector according to claim 1, wherein, The inner housing (50) is selectively fixed to the outer housing (82) by means of movement of the inner housing (50) relative to the outer housing (82) in a direction opposite to the insertion direction.

3. The connector according to claim 1 further includes a cable seal (92) arranged around the first cable opening (88) and adapted to form a seal with the FFC (10) inserted through the first cable opening (88).

4. The connector according to claim 1, wherein, The plurality of terminal openings (54) open toward the front end of the inner housing (50) and are adapted to mate with the corresponding mating terminals of the mating connector.

5. The connector according to claim 4, wherein, The plurality of terminal openings (54) are adapted to receive the plurality of terminals (30) therein from the rear end of the inner housing (50) opposite to the front end.

6. The connector according to claim 4 further includes an inner seal (90) disposed within the housing (82) and extending into a mating space adapted to receive a mating end of the mating connector.

7. The connector according to claim 1, wherein, The plurality of terminal openings (54) are arranged in a first row and a second row, wherein the first row and the second row are arranged on opposite sides of the second cable opening (56).

8. A cable assembly, comprising: A flexible flat cable (FFC) (10) includes a plurality of conductors (12) embedded in an insulating material (14), a portion of each conductor (12) being exposed through a corresponding opening (16) defined through the insulating material (14); The outer casing (82) defines an inner cavity (86) and a first cable opening (88), the first cable opening (88) being adapted to receive the FFC (10) in the insertion direction and communicating with the inner cavity (86); as well as An inner housing (50), selectively fixed to the outer housing (82) at least partially within the inner cavity (86), the inner housing (50) comprising: Multiple terminal openings (54) having multiple conductive terminals (30) arranged in the multiple terminal openings (54), each terminal (30) including a first end (34) and a second end (36, 38), the first end (34) being adapted to engage with a corresponding mating terminal of a mating connector, and the second end (36, 38) being electrically connected to an exposed portion of the exposed portion of the conductor (12) of the FFC (10); as well as The second cable opening (56) is aligned with the first cable opening (88) and receives the free end of the FFC (10) arranged to pass through the first cable opening (88).

9. The component according to claim 8, wherein, The inner housing (50) is selectively fixed to the outer housing (82) via relative movement of the inner housing (50) relative to the outer housing (82) in a direction opposite to the insertion direction.

10. The component of claim 8 further includes a cable seal (92) arranged around the first cable opening (88) and forming a seal with the insulation material (14) of the FFC (10).

11. The component of claim 8 further includes an inner seal (90) disposed within the cavity (86) of the housing (82) and having a sealing surface extending into a mating connector space adapted to receive a mating end of the mating connector.

12. The component according to claim 8, wherein, The terminal openings (54) formed through the inner housing (50) are arranged in a first row and a second row, the first row and the second row being oriented such that the second ends (36, 38) of the terminals (30) are arranged on each of the first side and the second side of the FFC (10) received in the second cable opening (56).

13. The component of claim 12, wherein, The FFC (10) includes openings (16) facing the top and bottom sides of the FFC (10) respectively, which engage with the second ends (36, 38) of the terminals (30) in the first row and the second row respectively.

14. The component of claim 12 further includes a reinforcing element (20), wherein the free end of the FFC (10) is wound 180 degrees around the reinforcing element.

15. The component of claim 14, wherein, When the free ends of the reinforcing element (20) and the FFC (10) are inserted into the second cable opening (56), an opening (16) formed to pass through one side of the insulating material (14) of the FFC (10) exposes the conductor (12) in the opposite facing direction for engagement with the second ends (36, 38) of the terminals (30) in the first row and the second row, respectively.

16. A method for manufacturing a flexible flat cable (FFC) system, comprising the following steps: Multiple conductive terminals (30) are arranged within the inner connector housing (50), each terminal (30) defining a soldering area (37) suitable for electrical connection to a conductor (12) of the FFC (10). Insert the free end of the FFC (10) into the cable opening (88) through the outer connector housing (82) in the first direction. After inserting the free end of the FFC (10) through the outer connector housing (82), the free end of the FFC (10) is inserted into the inner connector housing (50) such that the plurality of conductors (12) of the FFC (10) are aligned with the corresponding terminals of the plurality of terminals (30); The plurality of conductors (12) are soldered to the plurality of terminals (30); After the conductor (12) is soldered to the terminal (30), the inner connector housing (50) is inserted into the outer connector housing (82); as well as The inner connector housing (50) is mechanically fixed to the outer connector housing (82).

17. The method according to claim 16, wherein, The inner connector housing (50) is inserted into the outer connector housing (82) via relative movement between the inner connector housing (50) and the outer connector housing (82) in a second direction opposite to the first direction.

18. The method according to claim 17, wherein, When the inner connector housing (50) is inserted into the outer connector housing (82), the FFC (10) is biased in the second direction through the cable opening (88) in the outer connector housing (82).

19. The method of claim 16, further comprising the step of forming a seal between the cable opening (88) and the FFC (10) after the inner connector housing (50) and the outer connector housing (82) are secured together.

20. The method according to claim 19, wherein, The step of forming a seal between the cable opening (88) of the outer connector housing (82) and the FFC (10) includes the following steps: A cable seal (92) is arranged around the cable opening (88); and The cable seal (92) is bonded to the insulation material (14) of the FFC (10).

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