Flat flexible cable connector

Abstract

The connector (10) for a flat flexible cable (20) includes a housing (100) having a main body (110) and a cover (130), and a spring clip (200) disposed on the housing (100). The cover (130) is movable relative to the main body (110) between an open position (O) and a closed position (C). The spring clip (200) is resiliently deflectable by the cover (130). When the cover (130) is in the open position (O), the spring clip (200) is in a first state (S1) in which the spring clip (200) abuts against a conductor (27) exposed through an insulation (21) of the flat flexible cable (20) with a first contact force (F1). The spring clip (200) is in a second state (S2) in which, when the cover (130) is in the closed position (C), the spring clip (200) abuts against the conductor (27) with a second contact force (F2) greater than the first contact force (F1).

Description

[Technical Field]

[0001] This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 63 / 043,387, filed June 24, 2020.

[0002] The present invention relates to connectors, and more particularly to connectors for flat flexible cables. [Background technology]

[0003] As understood by those skilled in the art, a flat flexible cable (FFC) or flat flexible circuit is an electrical component comprised of at least one conductor (e.g., a metal foil conductor) embedded within a thin, flexible strip of insulation. Flat flexible cables have gained popularity across many industries by offering advantages over traditional "round wire" counterparts. Specifically, in addition to being thinner and lighter, FFCs allow for the implementation of large circuit paths much more easily than round wire-based configurations. As a result, FFCs are considered for many complex and / or high-volume applications, including wiring harnesses such as those used in automotive manufacturing.

[0004] Implementing or incorporating FFCs into existing wiring environments presents significant challenges. By way of example only, in automotive applications, FFC-based wiring harnesses must mate with potentially hundreds of existing components, including sub-harnesses and various electronic devices (e.g., lights, sensors, etc.), each with a defined, and sometimes standardized, connector or interface type. Thus, significant obstacles preventing the implementation of FFCs in these applications include the need to develop quick, robust, and low-resistance termination techniques that allow FFCs to be connectorized to mate with these existing connections.

[0005] A typical FFC can be realized by applying insulation to each side of a pre-patterned thin foil conductor and then bonding the sides together with an adhesive to enclose the conductor. Current FFC terminals include piercing-style crimp terminals, which use sharp teeth on the terminal to pierce the FFC's insulation and adhesive and establish a reliable electrical connection with the embedded conductor. However, in harsh environmental conditions, such connections are subject to metal plastic creep and stress relaxation, resulting in inconsistent electrical connectivity between the conductor and terminal and reduced mechanical reliability over time. Alternatively, terminals can be soldered to the FFC, but soldering adds assembly difficulties and requires inspection. Summary of the Invention [Means for solving the problem]

[0006] The connector for a flat flexible cable includes a housing and a spring clip disposed on the housing. The housing has a body and a cover. The cover is movable relative to the body between an open position and a closed position. The spring clip is resiliently deflectable by the cover. When the cover is in the open position, the spring clip is in a first state in which the spring clip abuts the conductors exposed through the insulation of the flat flexible cable with a first contact force. When the cover is in the closed position, the spring clip is in a second state in which the spring clip abuts the conductors with a second contact force greater than the first contact force.

[0007] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view of a connector assembly according to an embodiment. FIG. [Figure 2] 2 is a side cross-sectional view of a housing of the connector assembly of FIG. 1. [Figure 3] FIG. 2 is a cross-sectional perspective view of a connector of the connector assembly of FIG. 1. [Figure 4] 2 is a side cross-sectional view of the connector assembly of FIG. 1 with the cover in an open position. [Figure 5] 2 is a cross-sectional perspective view of the connector assembly of FIG. 1 with the cover in a closed position. [Figure 6] FIG. 10 is a perspective view of a connector assembly according to another embodiment, with the cover in an open position. [Figure 7] FIG. 7 is a perspective view of the main body of the connector assembly of FIG. 6. [Figure 8] FIG. 7 is a perspective view of a flat flexible cable of the connector assembly of FIG. 6. [Figure 9] FIG. 7 is a perspective view of a flat flexible cable inserted into the body of the connector assembly of FIG. 6. [Figure 10] FIG. 7 is a cross-sectional side view of the connector assembly of FIG. 6 in an open position. [Figure 11] FIG. 7 is a side cross-sectional view of the connector assembly of FIG. 6 in a closed position. [Figure 12] 7 is a cross-sectional side view of the connector assembly of FIG. 6 in a closed position, with the mounting ends of the posts formed as stake heads. [Figure 13] FIG. 10 is a cross-sectional side view of a connector assembly according to another embodiment in a closed position. [Figure 14] FIG. 14 is a cross-sectional perspective view of the connector assembly of FIG. 13 in a closed position. [Figure 15] FIG. 10 is a perspective view of a cover of a connector assembly according to another embodiment. [Figure 16] FIG. 16 is a side cross-sectional view of the connector of the connector assembly of FIG. 15 in an open position. [Figure 17] FIG. 16 is a side cross-sectional view of the connector assembly of FIG. 15 in a closed position. [Figure 18] FIG. 10 is a cross-sectional perspective view of a connector assembly according to another embodiment in a closed position. DETAILED DESCRIPTION OF THE INVENTION

[0009] A connector assembly 1 according to an embodiment is shown in Fig. 1. The connector assembly 1 includes a connector 10 and a flat flexible cable (FFC) 20 connected to the connector 10. As shown in Fig. 3, the connector 10 includes a housing 100 and a spring clip 200 disposed in the housing 100.

[0010] As shown in FIGS. 1 to 5, the housing 100 includes a main body 110 and a cover 130 that is movable relative to the main body 110 and that can be attached to the main body 110.

[0011] 1 and 2, the main body 110 has a plurality of clip-receiving passages 112 penetrating the main body 110 along the longitudinal direction L. The main body 110 has a closed portion 114 that surrounds the clip-receiving passages 112 in a height direction H perpendicular to the longitudinal direction L and in a width direction W perpendicular to both the height direction H and the longitudinal direction L. The main body 110 has an open portion 116 at the top of the clip-receiving passages 112 that is open in the height direction H. In the embodiment shown in FIGS. 1 to 5, the open portion 116 is open on at least a portion of each of a pair of opposite sides in the width direction W.

[0012] As shown in FIG. 2 , at the open portion 116, the body 110 has an inner surface 118 and an outer surface 120 opposite the inner surface 118 in the height direction H. The body 110 has a plurality of latches 124 that are disposed on the inner surface 118 of the open portion 116 and extend in the height direction H into the clip-receiving passages 112. Each of the latches 124 is positioned to extend into one of the clip-receiving passages 112. Although only one of the latches 124 is shown in FIG. 2 corresponding to one of the clip-receiving passages 112, the body 110 includes one latch 124 corresponding to each of the clip-receiving passages 112 shown in FIG. 1 .

[0013] Body 110 is formed from an insulating material. In embodiments, body 110 is formed as a single piece, integrally with closed portion 114 and open portion 116. In other embodiments, body 110 may be formed from multiple pieces that are assembled together to form body 110 as shown in Figures 1 and 2 and described above.

[0014] 2, the cover 130 has a plurality of beam-receiving passages 132 extending through the cover 130 in the longitudinal direction L. Although only one of the beam-receiving passages 132 corresponding to one of the clip-receiving passages 112 is shown in FIG. 2, the cover 130 includes one beam-receiving passage 132 corresponding to each of the clip-receiving passages 112 shown in FIG.

[0015] 2, in each beam-receiving passage 132, the cover 130 has an upper surface 134 that surrounds the beam-receiving passage 132 in a height direction H. The upper surface 134 has an upper flat portion 136 and an upper inclined portion 138 extending from the upper flat portion 136. The upper surface 134 is flat and extends parallel to a plane defined by the width direction W and the length direction L of the upper flat portion 136, and the upper flat portion 136 is parallel to the inner surface 118 of the open portion 116 of the body 110. In the upper inclined portion 138, the upper surface 134 extends in the height direction H toward the inner surface 118 at an oblique angle to the upper flat portion 136.

[0016] As shown in Fig. 2, in each of the beam receiving passages 132, the cover 130 has a pair of side surfaces 140 extending from the upper surface 134 along the height direction H. The pair of side surfaces 140 are disposed opposite each other in the width direction W and surround the beam receiving passage 132 in the width direction W. Although only one of the side surfaces 140 is shown in the cross-sectional view of Fig. 2, the other side surface is a mirror image of the side surface 140 shown in Fig. 2.

[0017] As shown in FIG. 2 , each side surface 140 has a ramp projection 142 extending in a width direction W into the beam-receiving passage 132. The ramp projection 142 has a ramp flat portion 144 and a ramp angled portion 146 extending from the ramp flat portion 144. The ramp flat portion 144 is parallel to the upper flat portion 136. The ramp angled portion 146 extends at an oblique angle relative to the ramp flat portion 144 and in the same direction as the upper ramp portion 138. In the illustrated embodiment, the ramp angled portion 146 extends from the ramp flat portion 144 at the same angle as the upper ramp portion 138 extends from the upper flat portion 136, and the ramp angled portion 146 and the upper ramp portion 138 are parallel to each other. The ramp flat portion 144 is spaced apart from the upper flat portion 136 along a height direction H, and the ramp angled portion 146 is spaced apart from the upper ramp portion 138 along both the height direction H and the longitudinal direction L.

[0018] Cover 130 is formed from an insulating material. In embodiments, cover 130 is formed as a single piece, integrally formed with top surface 134 and side surfaces 140. In other embodiments, cover 130 may be formed from multiple pieces that are assembled together to form cover 130 as shown in Figures 1 and 2 and described above.

[0019] As shown in FIG. 3, the spring clip 200 includes a first beam 210 and a second beam 260 connected to the first beam 210 at a connecting portion 290 .

[0020] 3 , the first beam 210 has a first connecting end 212 connected to the connecting portion 290 and extends away from the first connecting end 212 along the longitudinal direction L to a first free end 214. The first beam 210 has a first tab 215 at the first free end 214, and the width of the first tab 215 is greater than the width of the immediately adjacent portion of the first beam 210 in the width direction W. The first beam 210 has a first inner surface 216 facing toward the second beam 260 and a first outer surface 218 facing away from the second beam 260 in the height direction H.

[0021] 3 , the first beam 210 has a plurality of support protrusions 220 disposed between the first connecting end 212 and the first free end 214 along the longitudinal direction L and extending away from the first outer surface 218 in the height direction H. In the illustrated embodiment, the plurality of support protrusions 220 is two support protrusions 220 spaced apart from one another along the longitudinal direction L. In other embodiments, the support protrusions 220 may include only one support protrusion 220 or three or more support protrusions 220 spaced apart from one another along the longitudinal direction L. In embodiments, the support protrusions 220 may be formed by stamping or bending the first beam 210.

[0022] 3 , the second beam 260 has a second connecting end 262 connected to the connecting portion 290 and extends away from the second connecting end 262 along the longitudinal direction L to a second free end 264. The second beam 260 has a second tab 265 at the second free end 264, and the width of the second tab 265 is greater than the width of the immediately adjacent portion of the second beam 260 in the width direction W. The second beam 260 has a second inner surface 266 facing toward the first beam 210 and a second outer surface 268 facing away from the first beam 210 in the height direction H.

[0023] As shown in FIG. 3 , the second beam 260 has a first contact bend portion 270 and a second contact portion 272 between the second connecting end 262 and the second free end 264. The first contact bend portion 270 extends toward the first beam 210. In the illustrated embodiment, the second contact portion 272 is a second contact bend portion 274 similar to the first contact bend portion 270 and extends toward the first beam 210. The first contact bend portion 270 is located proximal to the second connecting end 262, and the second contact portion 272 is located proximal to the second free end 264. The second contact portion 272 is located farther from the connecting portion 290 than the first contact bend portion 270.

[0024] 3, the connecting portion 290 is a flexure 292 that connects the first beam 210 and the second beam 260. The second beam 260 is elastically deflectable about the flexure 292 toward the first beam 210.

[0025] The spring clip 200 is formed from a conductive material. The spring clip 200 may be formed from a single conductive material, such as copper or aluminum, or may be an alloy or include multiple layers of conductive material. In embodiments, the spring clip 200 has a coating over the conductive material, such as a tin coating. In the illustrated embodiment, the spring clip 200 is integrally formed with the first beam 210, the second beam 260, and the connecting portion 290 in a single piece. In other embodiments, the spring clip 200 may be formed from multiple pieces and assembled to form the spring clip 200 including the elements described above and shown in FIG. 3 .

[0026] 3 and 4 , to assemble connector 10, spring clips 200 are each inserted into one of clip-receiving passages 112 of body 110. Spring clips 200 are inserted along longitudinal direction L from open portion 116 into clip-receiving passages 112 of closed portion 114. Spring clip 200 is positioned with first free end 214 of first beam 210 adjacent latch 124, which holds spring clip 200 in position along longitudinal direction L in clip-receiving passage 112.

[0027] 4 , when the cover 130 is in the open position O, the cover 130 moves away from the body 110 at least along the longitudinal direction L and engages with the second beam 260. A second tab 265 at a second free end 264 of the second beam 260 is disposed between the ramp flat portion 144 and the upper flat portion 136 in the height direction H, and holds the spring clip 200 in the first state S1 when the cover 130 is in the open position O. In the first state S1, the second beam 260 is elastically deflected away from the first beam 210.

[0028] As shown in FIG. 4 , the FFC 20 is inserted into the connector 10 with the cover 130 in the open position O and the spring clip 200 in the first condition S1. As shown in FIGS. 1 and 4 , the FFC 20 includes an insulating material 21 and a plurality of flat conductors 27 embedded in the insulating material 21. In an embodiment, the flat conductors 27 are each, by way of example only, a metal foil such as a copper foil patterned into any desired configuration. The insulating material 21, such as a polymer insulating material, may be attached to one or both sides of the flat conductors 27 with an adhesive, or may be extruded directly onto the flat conductors 27. The flat conductors 27 may also be referred to herein as conductors 27.

[0029] As shown in Fig. 4, the insulating material 21 has an upper surface 22 and a lower surface 23 opposite the upper surface 22 in the height direction H. The conductor 27 is embedded in the insulating material 21 between the upper surface 22 and the lower surface 23. In the embodiment shown in Fig. 4, the FFC 20 has a peeled portion 24 in which the upper surface 22 of the insulating material 21 has been removed to expose a first surface 28 of the conductor 27. In the embodiment shown in Fig. 4, a second surface 29 of the conductor 27 opposite the first surface 28 in the height direction H is completely covered by the lower surface 23 of the insulating material 21 in the peeled portion 24.

[0030] 4 , with cover 130 in open position O and spring clip 200 in first state S1, peeled portion 24 is inserted into connector 10 between first beam 210 and second beam 260 in height direction H. Each of conductors 27 exposed in peeled portion 24 is positioned in one of clip-receiving passages 112 and corresponds to one of spring clips 200. In first state S1, spring clip 200 is deflected such that second beam 260 is away from first beam 210, facilitating insertion of FFC 20.

[0031] 4 , when the spring clip 200 is in the first state S1, which is the fully inserted position of the FFC 20, the first inner surface 216 of the first beam 210 abuts against the lower surface 23 of the insulating material 21 and is separated from the second surface 29 of the conductor 27 by the insulating material 21. In the first state S1, the first contact bent portion 270 of the second beam 260 abuts against the first surface 28 of the conductor 27 exposed through the insulating material 21 of the peeled portion 24 with a first contact force F1. In the first state S1, the spring clip 200 is electrically connected to the conductor 27 through the first contact bent portion 270. In the first state S1, the second contact portion 272 is separated from the conductor 27.

[0032] The cover 130 moves from the open position O, shown in FIG. 4 , along the longitudinal direction L toward the body 110 to the closed position C, shown in FIG. 5 . As the cover 130 moves toward the body 110, the second free end 264 of the second beam 260 initially slides between the upper flat portion 136 and the ramp flat portion 144, maintaining the second beam 260 in the first state S1, shown in FIG. 4 , deflected away from the second beam 260. As the cover 130 moves in the longitudinal direction L, the second free end 264 moves along the upper flat portion 136 to the upper inclined portion 138. Upon reaching the upper inclined portion 138, the second free end 264 slides between the upper inclined portion 138 and the ramp inclined portion 146 as the cover 130 continues to move toward the closed position C. As the second free end 264 abuts against and slides along the upper inclined portion 138 , the second beam 260 is gradually deflected in the height direction H toward the first beam 210 .

[0033] 5, the second beam 260 is held in the second state S2 of the spring clip 200, where the second beam 260 is maximally deflected by the cover 130 toward the first beam 210. In the second state S2, the deflection of the second beam 260 toward the first beam 210 causes the first contact bent portion 270 to abut against the first surface 28 of the conductor 27 with a second contact force F2 that is greater than the first contact force F1. In the illustrated embodiment, in the second state S2, the second contact portion 272 and the second contact bent portion 274 also abut against the first surface 28 of the conductor 27 exposed through the insulation 21 of the stripped portion 24. In the second state S2, the first contact bend portion 270 and the second contact portion 272 electrically connect the spring clip 200 to the conductors 27 of the FFC 20 at multiple contact points.

[0034] 5, cover 130 can be attached to body 110 to hold spring clip 200 in second state S2 electrically connected to conductors 27 of FFC 20. In embodiments, cover 130 can be releasably attached to body 110, for example, by a resilient latch. In other embodiments, cover 130 can be non-releasably secured to body 110 in closed position C, for example, by ultrasonic welding.

[0035] The cover 130 moves relative to the body 110 between an open position O and a closed position C, and the spring clip 200 correspondingly moves between a first state S1 and a second state S2, allowing the FFC 20 to be easily inserted into the connector 10 in the open position O and enabling a robust electrical connection between the spring clip 200 and the FFC 20 in the closed position C. The large second contact force F2 in the closed position C enables a low-resistance mechanical and electrical connection between the FFC 20 and the spring clip 200, and the multiple contact points in the first beam 210, the first contact bend portion 270, and the second contact portion 272 prevent rotation and increase vibration resistance of the connection.

[0036] 5, the connector assembly 1 can be mated with a mating element, which electrically connects to the FFC 20 through the spring clip 200. In the illustrated embodiment, the spring clip 200, which includes a curved portion 292 as the connecting portion 290, can be mated to a tuning fork inserted into the housing 100. In other embodiments including other connecting portions 290, the spring clip 200 can be mated to some other electrical terminal, such as a pin.

[0037] A connector assembly 1 according to another embodiment is shown in Figures 6 to 12. The same reference numerals indicate the same elements, and differences from the connector assembly 1 shown in Figures 1 to 5 will mainly be described here.

[0038] As shown in FIG. 6, the housing 100 includes a main body 110 and a cover 130 that is movable relative to the main body 110.

[0039] 6 and 7, the body 110 has a plurality of slots 126 that extend through the opening 116 in the height direction H, and a plurality of posts 128 that are disposed on the inner surface 118 of the opening 116 and extend away from the inner surface 118 in the height direction H. In the illustrated embodiment, the posts 128 are integrally formed with the body 110 in a single piece. In the illustrated embodiment, the body 110 has three slots 126 and three posts 128, although the number and arrangement of the slots 126 and posts 128 in the opening 116 may differ from the illustrated embodiment.

[0040] As shown in FIGS. 6 and 11 , the cover 130 has an outer surface 150 and an inner surface 152 opposite the outer surface 150 in a height direction H. The cover 130 has a plurality of pegs 154 extending from the inner surface 152 in the height direction H. Each of the pegs 154 is attached to the cover 130 at a connecting end 156 and extends away from the cover 130 in the height direction H to an attachment end 158. Although only one of the plurality of pegs 154 is visible in FIGS. 6 and 11 , the pegs 154 are distributed along the inner surface 152 in an arrangement corresponding to the number and location of the slots 126 in the body 110. In various embodiments, the number and location of the pegs 154 extending from the cover 130 may vary, as long as they correspond to the slots 126 in the body 110.

[0041] As shown in FIGS. 6 and 11 , the cover 130 has a front surface 176, a rear surface 180, and a pair of side surfaces 190 extending in a height direction H between the outer surface 150 and the inner surface 152. The front surface 176 has a plurality of front fasteners 178 protruding from the front surface 176 in a longitudinal direction L. Each of the side surfaces 190 has a side fastener 192 extending from the side surface 190 in a width direction W. In the illustrated embodiment, the front surface 176 has four front fasteners 178, and each side surface 190 has one side fastener 192. In other embodiments, the number and arrangement of the front fasteners 178 and side fasteners 192 may be different, as long as the front fasteners 178 and side fasteners 192 can perform the functions described below.

[0042] The cover 130 is formed from an insulating material. In the embodiment shown in Figures 6 and 11, the cover 130 is integrally formed from a single piece. In other embodiments, the cover 130 may be formed from multiple pieces that are assembled together to form the cover 130 shown in Figures 6 and 11.

[0043] In the connector assembly 1 according to the embodiment of FIGS. 6 to 12, as shown in FIGS. 6, 9, and 10, the connector 10 includes a spring clip 200. As shown in FIG. 10, the spring clip 200 includes a plurality of contact protrusions 240 extending in a height direction H from a first inner surface 216 of a first beam 210 toward a second beam 260. The contact protrusions 240 are spaced apart from one another along a longitudinal direction L. In the illustrated embodiment, one of the contact protrusions 240 is aligned with a first contact bend portion 270 along the longitudinal direction L, and the other of the contact protrusions 240 is aligned with a second contact portion 272 along the longitudinal direction L. The contact protrusions 240 can be formed by stamping or bending the first beam 210. In other embodiments, instead of contact protrusions 240, first beam 210 may have multiple serrations or multiple piercing elements.

[0044] In the connector assembly 1 according to the embodiment of FIGS. 6 to 12, as shown in FIG. 8, the FFC 20 has a plurality of peg openings 25 and a plurality of post openings 26 that penetrate the insulation 21 in the height direction H. The peg openings 25 and the post openings 26 penetrate the insulation 21 outside the peeled portion 24 and are each disposed between a pair of conductors 27 in the width direction W. The peg openings 25 are aligned with each other along the width direction W, and the post openings 26 are aligned with each other along the width direction W. The peg openings 25 are disposed closer to the peeled portion 24 than the post openings 26 along the longitudinal direction L. In the illustrated embodiment, the FFC 20 has three peg openings 25 and three post openings 26. In other embodiments, the number and arrangement of peg openings 25 may be different as long as they correspond to the pegs 154 of the cover 130, and the number and arrangement of post openings 26 may be different as long as they correspond to the posts 128 of the body 110.

[0045] 9 and 10, the spring clips 200 are inserted into the clip-receiving passages 112 of the body 110 and are held in the longitudinal direction L by engaging the latches 124, as described in the embodiment of FIGS. 1-5. Each of the spring clips 200 is in an undeflected state in the first state S1 of the spring clips 200 shown in FIGS. 9 and 10. In the first state S1, the second free end 264 of the second beam 260 is disposed in the open portion 116 and exposed to the outside of the body 110.

[0046] 6, 9, and 10, the FFC 20 is inserted into the body 110 with the spring clip 200 in the first position S1. The FFC 20 is inserted until the peg openings 25 align with the slots 126 and the posts 128 extend through the post openings 26. The posts 128 extend through the post openings 26 to provide strain relief if the FFC 20 is pulled or otherwise moved, and also to position the FFC 20 within the body 110.

[0047] 10 , when the FFC 20 is fully inserted into the main body 110, the contact protrusion 240 abuts against the lower surface 23 of the insulating material 21. In the first state S1, the first contact bent portion 270 of the second beam 260 abuts against the first surface 28 of the conductor 27 exposed through the insulating material 21 of the peeled portion 24 with a first contact force F1. In the first state S1, the spring clip 200 is electrically connected to the conductor 27 through the first contact bent portion 270. In the first state S1, the second contact portion 272 is separated from the conductor 27. FIGS. 6 and 10 , in which the cover 130 is removed from the main body 110 and the spring clip 200 is in the first state S1, correspond to the open position O of the illustrated embodiment.

[0048] The cover 130 is positioned on the body 110 from the open position O shown in FIGS. 6 and 10 . As shown in FIG. 11 , the pegs 154 are each inserted into one of the peg openings 25 and one of the slots 126, which are aligned with one another. In an embodiment, the pegs 154, peg openings 25, and slots 126 are each asymmetrically positioned to ensure that the cover 130 can only move in specific directions toward the closed position C. As the cover 130 moves in the height direction H toward the body 110, the inner surface 152 contacts the second free end 264, deflecting the second beam 260 toward the first beam 210.

[0049] The cover 130 is moved toward the body 110, and the peg 154 is inserted until the inner surface 152 abuts the FFC 20 in the closed position C of the cover 130 shown in FIG. 11 . In the closed position C, the second beam 260 is held in the second state S2 of the spring clip 200, in which the second beam 260 is maximally deflected toward the first beam 210 by the cover 130. In the second state S2, the deflection of the second beam 260 toward the first beam 210 causes the first contact bending portion 270 to abut against the first surface 28 of the conductor 27 with a second contact force F2 greater than the first contact force F1. In the illustrated embodiment, in the second state S2, the second contact portion 272 and the second contact bending portion 274 also abut against the first surface 28 of the conductor 27 exposed through the insulation 21 of the stripped portion 24. In the second state S2, the first contact bend portion 270 and the second contact portion 272 electrically connect the spring clip 200 to the conductors 27 of the FFC 20 at multiple contact points. In other embodiments, the FFC 20 may have a window through which the conductors 27 are exposed and through which the contact protrusions 240 and / or the first contact bend portion 270 and the second contact portion 272 can contact the conductors 27.

[0050] In the closed position C shown in FIG. 11 , the pegs 154 extend through the peg openings 25 and slots 126, with the attachment ends 158 extending beyond the exterior surface 120 of the body 110. The cover 130 is initially latched into the closed position C by the front fasteners 178 and side fasteners 192 engaging the body 110. As shown in FIG. 12 , the cover 130 is further secured in the closed position C by ultrasonically welding the attachment ends 158. The ultrasonic welding melts and deforms the attachment ends 158, forming them as staked heads 160. In another embodiment, the attachment ends 158 can be heat staked to the staked heads 160. The staked heads 160 extend beyond the slots 126 and engage the exterior surface 120 of the body 110, securing the cover 130 in the closed position C. In an embodiment, the cover 130 is secured to the body 110 simply by forming the mounting end 158 on the stake head 160 .

[0051] A connector assembly 1 according to another embodiment is shown in Figures 13 and 14. The same reference numerals indicate the same elements, and differences from the connector assembly 1 shown in Figures 6 to 12 will mainly be described here.

[0052] 13, the peg 154 of the cover 130 has a pair of resilient arms 162 that extend beyond the inner surface 152 along the height direction H. Each of the resilient arms 162 has a fastener 164 that extends beyond a side of the resilient arm 162. The peg 154 has an opening 166 disposed between the resilient arms 162, and the resilient arms 162 are connected to each other at ends distal from the inner surface 152. The resilient arms 162 are resiliently deflectable toward the openings 166 and toward each other.

[0053] 13 and 14 , when the cover 130 is inserted into the closed position C, the resilient arms 162 are biased toward each other as the fasteners 164 pass through the peg openings 25 and the slots 126. When the fasteners 164 pass through the outer surface 120 of the body 110, the resilient arms 162 resiliently return from the biased state to the position shown in FIG. 13 . The fasteners 164 each engage with the seats 122 of the body 110 at the outer surface 120, securing the cover 130 in the closed position C on the body 110. As shown in FIG. 14 , the closed position C of the cover 130 holds the spring clip 200 in the second condition S2.

[0054] A connector assembly 1 according to another embodiment is shown in Figures 15 to 17. The same reference numerals indicate the same elements, and differences from the connector assembly 1 shown in Figures 13 and 14 will mainly be described here.

[0055] 15 , each of the pegs 154 of the cover 130 has a resilient arm 162 and a curved arm 170 extending adjacent to each other from the inner surface 152. The resilient arm 162 has a fastener 164 at its free end and is resiliently deflectable toward the curved arm 170 and into an opening 172 between the resilient arm 162 and the curved arm 170. The curved arm 170 has a fixed position relative to the cover 130. The cover 130 has a hinge 174 at its front surface 176.

[0056] 16 and 17, the cover 130 is attached to the main housing 110 with a hinge 174 and is rotatable relative to the main housing 110 between an open position O and a closed position C. In the illustrated embodiment, the hinge 174 is part of the cover 130 and is separate from the main housing 110. In another embodiment, the cover 130 may be formed integrally with the main housing 110 and the hinge 174 may be a flexible portion of the one piece, such as a plastic hinge.

[0057] In an embodiment, the cover 130 can be releasably held in the open position O shown in FIG. 16 while the FFC 20 remains inserted in the connector 10. The cover 130 pivots from the open position O about the hinge 174. As the cover 130 pivots toward the closed position C, the catch 164 abuts the body 110 at the slot 126, biasing the resilient arm 162 toward the curved arm 170. When the catch 164 reaches the outer surface 120, the resilient arm 162 resiliently returns to the closed position C shown in FIG. 17, where the catch 164 engages the outer surface 120 and secures the cover 130 in the closed position C on the body 110. As shown in FIG. 17, the closed position C of the cover 130 holds the spring clip 200 in the second condition S2.

[0058] A connector assembly 1 according to another embodiment is shown in Figure 18. The same reference numerals indicate the same elements, and differences from the connector assembly 1 according to the above embodiment will be mainly described here. The connector assembly 1 shown in Figure 18 includes a spring clip 200 according to another embodiment.

[0059] 18 , the spring clip 200 has a pin interface 294 as the connecting portion 290. In the illustrated embodiment, the pin interface 294 is a box-spring interface configured to resiliently abut and electrically connect to a contact pin. In other embodiments, the pin interface 294 may be any type of interface configured to electrically connect to a contact pin, connected to the first beam 210 and the second beam 260, and allowing for resilient deflection of the second beam 260 toward the first beam 210.

[0060] 18 , second contact portion 272 is a friction lock 280 instead of a second contact bend 274. Friction lock 280 includes a bend 282 in second beam 260 that is bent back toward connection portion 290 and first beam 210. Bend 282 terminates at an edge 286 extending in width direction W. In various embodiments, bend 282 can be bent back toward connection portion 290 at an angle between 90 degrees and 180 degrees, or at any other angle that allows engagement of friction lock 280 with conductor 27, as described below.

[0061] 18 , with cover 130 in the closed position C and spring clip 200 in the second state S2, cover 130 compresses friction lock 280 to engage conductor 27. In second state S2, bend 282 is held in a position where edge 286 of bend 282 and / or the curved portion adjacent edge 286 mechanically and electrically engages conductor 27 at first surface 28 of conductor 27. In embodiments where edge 286 engages first surface 28 of conductor 27, edge 286 bites into first surface 28 but does not completely penetrate conductor 27. As FFC 20 is moved or pulled in the longitudinal direction L, bend 282 resists movement because it resists rotation from the bent state shown in FIG. 18; the harder FFC 20 is pulled, the stronger the engagement between edge 286 and / or curved portion of bend 282 and conductor 27, and the greater the resistance to movement of FFC 20.

[0062] In the spring clip 200 of FIG. 18 , an embodiment of the cover 130 has an attachment end 158 formed to the stake head 160 in the closed position C, as shown in the embodiment of FIG. 12 . However, the spring clip 200 including the friction lock 280 can be used with any of the embodiments of the cover 130 described herein in which the bent portion 282 is compressed and the edge 286 engages the conductor 27 in the closed position C. While the friction lock 280 is shown as part of an embodiment including the pin interface 294 as the connecting portion 290, it may instead be used in the same manner as the connecting portion 290 as the bent portion 292 in other embodiments described herein. The pin interface 294 may similarly be used with any of the embodiments of the spring clip 200 described herein that include, for example, the second contact portion 272 embodied as a second contact bend portion 274.

Claims

1. A connector (10) for a flat flexible cable (20), comprising: a housing (100) including a body (110) and a cover (130), the cover (130) being movable relative to the body (110) between an open position (O) and a closed position (C); a spring clip (200) disposed on the housing (100), the spring clip (200) being resiliently deflectable by the cover (130), the spring clip (200) being in a first state (S1) in which the spring clip (200) abuts against a conductor (27) exposed through an insulating material (21) of the flat flexible cable (20) with a first contact force (F1) when the cover (130) is in the open position (O), and the spring clip (200) being in a second state (S2) in which the spring clip (200) abuts against the conductor (27) with a second contact force (F2) greater than the first contact force (F1) when the cover (130) is in the closed position (C); Equipped with The spring clip (200) includes a first beam (210) and a second beam (260) connected to the first beam (210), the second beam (260) being resiliently deflectable toward the first beam (210) by the cover (130); The cover (130) has a beam receiving passage (132) including a top surface (134) and a pair of side surfaces (140), each of the side surfaces (140) having a lamp projection (142) extending into the beam receiving passage (132).

2. 2. The connector (10) of claim 1, wherein the upper surface (134) has an upper flat portion (136) and an upper inclined portion (138), the ramp protrusion (142) has a ramp flat portion (144), the second beam (260) has an end (264) that is disposed between the upper flat portion (136) and the ramp flat portion (144) in the first state (S1), and the end (264) of the second beam (260) abuts the upper inclined portion (138) to thereby elastically deflect toward the first beam (210) to the second state (S2).

3. 2. The connector (10) of claim 1, wherein the main body (110) has a closed portion (114) and an open portion (116), the second beam (260) has a free end (264) that is disposed in the open portion (116) and exposed to the outside of the main body (110) in the first state (S1), and the cover (130) abuts the free end (264) of the second beam (260) in the closed position (C) to move the spring clip (200) to the second state (S2).

4. 2. The connector (10) of claim 1, wherein the second beam (260) has a first contact bending portion (270) extending toward the first beam (210), and the first contact bending portion (270) abuts against the conductor (27) with the first contact force (F1) in the first state (S1) and abuts against the conductor (27) with the second contact force (F2) in the second state (S2).

5. 5. The connector (10) of claim 4, wherein the first beam (210) and the second beam (260) are connected at a connection portion (290), the second beam (260) has a second contact portion (272) positioned farther from the connection portion (290) than the first contact bend portion (270), and the second contact portion (272) abuts against the conductor (27) in the second state (S2).

6. The connector (10) of claim 5, wherein the second contact portion (272) is a second contact bend (274) that extends toward the first beam (210).

7. A connector (10) for a flat flexible cable (20), comprising: a housing (100) including a body (110) and a cover (130), the cover (130) being movable relative to the body (110) between an open position (O) and a closed position (C); a spring clip (200) disposed on the housing (100), the spring clip (200) being resiliently deflectable by the cover (130), the spring clip (200) being in a first state (S1) in which the spring clip (200) abuts against a conductor (27) exposed through an insulating material (21) of the flat flexible cable (20) with a first contact force (F1) when the cover (130) is in the open position (O), and the spring clip (200) being in a second state (S2) in which the spring clip (200) abuts against the conductor (27) with a second contact force (F2) greater than the first contact force (F1) when the cover (130) is in the closed position (C); Equipped with The spring clip (200) includes a first beam (210) and a second beam (260) connected to the first beam (210), the second beam (260) being resiliently deflectable toward the first beam (210) by the cover (130); The connector (10) has a main body (110) having a closed portion (114) and an open portion (116), the second beam (260) has a free end (264) that is disposed in the open portion (116) and exposed to the outside of the main body (110) in the first state (S1), and the cover (130) abuts the free end (264) of the second beam (260) in the closed position (C) to move the spring clip (200) to the second state (S2).

8. 8. The connector (10) of claim 7, wherein the cover (130) has a peg (154) extending from an inner surface (152) of the cover (130) to a mounting end (158) of the peg (154), the mounting end (158) passing through a slot (126) in the open portion (116) of the housing (100) in the closed position (C).

9. The connector (10) of claim 8, wherein the mounting end (158) is formed into a stake head (160) to secure the cover (130) in the closed position (C).

10. The connector (10) of claim 8, wherein the peg (154) includes a resilient arm (162) having a catch (164) that engages the housing (100) in the closed position (C).

11. The connector (10) of claim 10, wherein the peg (154) includes a curved arm (170), and the resilient arm (162) is deflectable toward the curved arm (170).

12. 12. The connector (10) of claim 11, wherein the cover (130) is connected to the housing (100) by a hinge (174) and is pivotable about the hinge (174) between the open position (O) and the closed position (C).

13. 8. The connector (10) of claim 7, wherein the second beam (260) has a first contact bending portion (270) extending toward the first beam (210), and the first contact bending portion (270) abuts against the conductor (27) with the first contact force (F1) in the first state (S1) and abuts against the conductor (27) with the second contact force (F2) in the second state (S2).

14. 14. The connector (10) of claim 13, wherein the first beam (210) and the second beam (260) are connected at a connection portion (290), the second beam (260) has a second contact portion (272) positioned farther from the connection portion (290) than the first contact bend portion (270), and the second contact portion (272) abuts against the conductor (27) in the second state (S2).

15. 15. The connector (10) of claim 14, wherein the second contact portion (272) is a second contact bend portion (274) extending toward the first beam (210) or a friction lock (280) including the connection portion (290) and a bend portion (282) of the second beam (260) folded back toward the first beam (210).

16. A connector (10) for a flat flexible cable (20), comprising: a housing (100) including a body (110) and a cover (130), the cover (130) being movable relative to the body (110) between an open position (O) and a closed position (C); a spring clip (200) disposed on the housing (100), the spring clip (200) being resiliently deflectable by the cover (130), the spring clip (200) being in a first state (S1) in which the spring clip (200) abuts against a conductor (27) exposed through an insulating material (21) of the flat flexible cable (20) with a first contact force (F1) when the cover (130) is in the open position (O), and the spring clip (200) being in a second state (S2) in which the spring clip (200) abuts against the conductor (27) with a second contact force (F2) greater than the first contact force (F1) when the cover (130) is in the closed position (C); Equipped with The spring clip (200) includes a first beam (210) and a second beam (260) connected to the first beam (210), the second beam (260) being resiliently deflectable toward the first beam (210) by the cover (130); The second beam (260) has a first contact bending portion (270) extending toward the first beam (210), and the first contact bending portion (270) abuts against the conductor (27) with the first contact force (F1) in the first state (S1) and abuts against the conductor (27) with the second contact force (F2) in the second state (S2); The connector (10) includes a first beam (210) and a second beam (260) connected at a connection portion (290), the second beam (260) having a second contact portion (272) positioned farther from the connection portion (290) than the first contact bend portion (270), and the second contact portion (272) abuts against the conductor (27) in the second state (S2).

17. 17. The connector (10) of claim 16, wherein the second contact portion (272) is a second contact bend portion (274) extending toward the first beam (210) or a friction lock (280) including the connection portion (290) and a bend portion (282) of the second beam (260) folded back toward the first beam (210).

18. A connector assembly (1), comprising: A flat flexible cable (20) having an insulating material (21) and a plurality of conductors (27) embedded in the insulating material (21), the plurality of conductors (27) being exposed through a portion of the insulating material (21); A connector (10) according to any one of claims 1 to 17; A connector assembly comprising:

19. A connector assembly (1), comprising: A flat flexible cable (20) having an insulating material (21) and a plurality of conductors (27) embedded in the insulating material (21), the plurality of conductors (27) being exposed through a portion of the insulating material (21); The connector according to any one of claims 7 to 17, Equipped with The flat flexible cable (20) has a post opening (26) that penetrates the insulating material (21), and the body (110) has a post (128) that penetrates the post opening (26) in the open position (O) and the closed position (C).

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