Cable housings and connectors for flat flexible cables

Abstract

To provide a termination technique which is simple, secure, and in a low resistance by connecting an existing connection part with an FFC.SOLUTION: A plurality of flat conductors (120) that is exposed in a window extending through an insulation material of a flat flexible cable, is disposed between a first cable housing (210) and a second cable housing (250). When a first directing guide part (220) is moved to a second directing open part (270), and the first cable housing (210) is in a fitting position (M) with the second cable housing, the first directing guide part (220) comes into contact with a pair of flat conductors (120) of the plurality of flat conductors (120) to rotate each rotated part (140) of each flat conductor (120) to a rotated orientation. The rotated orientation of the rotated part (140) is arranged with an angle relative to a planer portion of each of the flat conductors (120) in the insulation material.SELECTED DRAWING: Figure 5D

Description

Technical Field

[0001] The present disclosure relates to connectors, and more particularly to connectors for flat flexible cables and cable housings for connectors.

Background Art

[0002] As will be appreciated by those skilled in the art, a flat flexible cable (FFC) or flat flexible circuit is an electrical component consisting of at least one conductor (e.g., a metal foil conductor) embedded in a thin flexible strip of insulator. Flat flexible cables are growing in popularity across many industrial fields due to their superior advantages over conventional "round wires", their counterparts. Specifically, compared with configurations using round wires, FFCs are lower in profile and lighter in weight, and far more easily enable implementation of large circuit paths. As a result, FFCs are being considered for many complex and / or high-volume applications, including wiring harnesses used in automobile manufacturing and the like.

[0003] The implementation or integration of FFCs into existing wiring environments is not without significant challenges. By way of example only, in automotive applications, a wiring harness using FFC needs to mate with approximately hundreds of existing components, including sub-harnesses and various electronic devices (e.g., lights, sensors, etc.) each having established, and in some cases standardized, connector or interface types. Therefore, as a significant obstacle hindering the implementation of FFCs in these applications, there is a need to develop a simple, robust and low-resistance termination technique that enables FFCs to be connectorized for mating with these existing connection parts.

Summary of the Invention

Problem to be Solved by the Invention

[0004] A typical FFC is realized by attaching insulating material to both sides of a pre-patterned thin conductive foil and bonding the two sides together with adhesive to enclose the conductor inside. Current FFC terminals include piercing-type crimp terminals that use the sharp teeth of the terminal to pierce the insulator and adhesive material of the FFC in an attempt to establish a stable electrical connection with the embedded conductor. However, under harsh environmental conditions, such connections undergo plastic creep and stress relaxation of the metal, resulting in mismatches in electrical connectivity and a lack of mechanical reliability between the conductor and the terminal over time. [Means for solving the problem]

[0005] A cable housing for a flat flexible cable includes a first cable housing having a first orientation guide and a second cable housing having a second orientation opening. Multiple flat conductors exposed in a window extending through the insulating material of the flat flexible cable are arranged between the first and second cable housings. When the first orientation guide moves to the second orientation opening and the first cable housing is in a mating position with the second cable housing, the first orientation guide contacts a pair of flat conductors among the multiple flat conductors, rotating each rotated portion of the flat conductors to a rotated orientation. The rotated orientation of the rotating portion is positioned at an angle to each flat portion of the flat conductor in the insulating material.

[0006] Here, the present invention will be described as an example with reference to the attached drawings. [Brief explanation of the drawing]

[0007] [Figure 1] This is a perspective view of a connector assembly according to one embodiment. [Figure 2]This is a perspective view of a flat flexible cable in a connector assembly. [Figure 3] A perspective view of the first cable housing of the connector cable housing of the connector assembly. [Figure 4] This is a perspective view of the second cable housing. [Figure 5A] This is a cross-sectional side view of the first step in which a first cable housing is fitted with a second cable housing around the flat conductor of a flat flexible cable. [Figure 5B] This is a cross-sectional side view of the second step, in which the first cable housing is fitted with the second cable housing around the flat conductor. [Figure 5C] This is a cross-sectional side view of the third step, in which the first cable housing is fitted with the second cable housing around the flat conductor. [Figure 5D] This is a cross-sectional perspective view showing the mating state of the first cable housing with the second cable housing around the flat conductor. [Figure 5E] This is another cross-sectional perspective view of the mating state of the first cable housing with the second cable housing around the flat conductor. [Figure 6] This is a perspective view of the connector terminals. [Figure 7] This is a perspective view of the contact housing of a connector that holds terminals. [Figure 8A] This is a cross-sectional side view of the first step in inserting the terminals in the contact housing into the cable housing. [Figure 8B] This is a cross-sectional side view of the second step in inserting the terminals in the contact housing into the cable housing. [Figure 8C] This is a cross-sectional side view of the third step in inserting the terminals in the contact housing into the cable housing. [Figure 9] This is a cross-sectional side view of the terminals in the contact housing, fully inserted into the cable housing in the assembled connector position. [Figure 10]This is a perspective view of a terminal according to another embodiment. [Figure 11] This is a perspective view of a terminal according to another embodiment. [Modes for carrying out the invention]

[0008] Figure 1 shows a connector assembly 1 according to one embodiment. The connector assembly 1 includes a flat flexible cable (FFC) 100 and a connector 10 connected to the FFC 100. The connector 10 includes a cable housing 200 arranged around the FFC 100, a plurality of terminals 300 connected to the FFC 100, and a contact housing 400 in which the terminals 300 are arranged.

[0009] As shown in Figure 2, the FFC 100 includes an insulating material 110 and a plurality of flat conductors 120 embedded in the insulating material 110. In one embodiment, each of the flat conductors 120 is a metal foil, such as copper foil, patterned to any desired configuration. The insulating material 110, such as a polymer insulating material, may be attached to one or both sides of the flat conductors 120 with an adhesive material, or it may be directly extruded onto the flat conductors 120.

[0010] As shown in Figure 2, the FFC 100 has a window 150 through which a portion of the insulating material 110 has been removed. The flat conductor 120 is exposed in the window 150. In the illustrated embodiment, the window 150 extends through the insulating material 110 in the central part of the FFC 100 along the longitudinal direction L. In other embodiments, the window 150 may extend through the insulating material 110 at the end of the FFC 100 along the longitudinal direction L, or at any other part along the FFC 100 in the longitudinal direction L.

[0011] As shown in FIG. 1, the cable housing 200 includes a first cable housing 210 and a second cable housing 250 that is fitted and attached to the first cable housing 210. The FFC 100 is held between the first cable housing 210 and the second cable housing 250.

[0012] As shown in FIG. 3, the first cable housing 210 has a first upper surface 212 and a first lower surface 214 opposite the first upper surface 212 in a vertical direction V perpendicular to a longitudinal direction L.

[0013] The first cable housing 210 has a plurality of first catches 216 extending from the first upper surface 212 in the vertical direction V. As shown in the embodiments of FIG. 3 and FIG. 5D, the first catches 216 are arranged at a plurality of edge portions of the first upper surface 212 opposite to each other in a width direction W perpendicular to the longitudinal direction L. In the illustrated embodiment, each first catch 216 has a substantially triangular cross-section with a flat surface facing inward of the first cable housing 210 and an inclined surface facing outward of the first cable housing 210. In other embodiments, as will be described in detail below, the first catch 216 may have other shapes and structures as long as the first catch 216 can be releasably fixed to an element of the second cable housing 250.

[0014] As shown in FIG. 3, the first cable housing 210 has a plurality of first orientation guide portions 220 extending from the first lower surface 214 in the vertical direction V. Each of the first orientation guide portions 220 has a plurality of first curved surfaces 222 at the free end of the first orientation guide portion 220 opposite to the first lower surface 214. In the illustrated embodiment, each first orientation guide portion 220 is a post having a substantially square cross-section, and has four first curved surfaces 222 at the free end. In other embodiments, the first orientation guide portions 220 may have other cross-sectional shapes with different numbers of first curved surfaces 222 at the free ends.

[0015] In the embodiment shown in Figure 3, the first cable housing 210 has a plurality of first orientation guide portions 220 arranged in a plurality of rows. Each of these rows extends along the width direction W and is spaced apart from each other in the longitudinal direction L. In the illustrated embodiment, the first cable housing 210 includes twelve first orientation guide portions 220, and four orientation guide portions 220 are arranged in each of the three rows. In other embodiments, the number of rows may be one, two, or more than three, and the first cable housing 210 may have any number of first orientation guide portions 220.

[0016] As shown in Figure 3, the first cable housing 210 has a plurality of first alignment wall portions 226 extending from a first lower surface 214 in the vertical direction V. Each of the first alignment wall portions 226 is an elongated member extending along the longitudinal direction L. In the illustrated embodiment, each of the first alignment wall portions 226 is connected to and extends from one of the first orientation guide portions 220. Each of the first alignment wall portions 226 has a chamfered surface 228 at a free end opposite to the first lower surface 214. In the illustrated embodiment, the number of the first alignment wall portions 226 is less than the number of the first orientation guide portions 220, and the first alignment wall portions 226 extend from only some of the first orientation guide portions 220.

[0017] As shown in Figure 3, the first cable housing 210 has a plurality of first directional openings 230 that extend in the vertical direction V toward the first lower surface 214. Each of the first directional openings 230 has a shape corresponding to the shape of the first directional guide portion 220 and is positioned adjacent to one of the first directional guide portions 220. In the illustrated embodiment, the first directional openings 230 are arranged in the same row as the first directional guide portions 220, and are arranged alternately with the first directional guide portions 220 in each row. Since the start and end of each row is one of the first directional openings 230, in the illustrated embodiment the number of first directional openings 230 is greater than the number of first directional guide portions 220, but in other embodiments the start and end of each row may be one of the first directional guide portions 220.

[0018] As shown in Figure 3, the first cable housing 210 has a plurality of first alignment recesses 232 that extend in the vertical direction V to the first lower surface 214. Each of the first alignment recesses 232 has a shape corresponding to the shape of the first alignment wall 226 and is positioned adjacent to one of the first alignment wall 226. In the illustrated embodiment, each of the first alignment recesses 232 is connected to one of the first directional openings 230 and extends from one of the first directional openings 230 along the longitudinal direction L. In the illustrated embodiment, the number of first alignment recesses 232 is less than the number of first directional openings 230, and the first alignment recesses 232 extend from only a portion of the first directional openings 230.

[0019] As shown in Figure 3, the first cable housing 210 has a plurality of first support ribs 234 extending from a first lower surface 214 in the vertical direction V, and a plurality of first notches 236 are arranged between the first support ribs 234. The first support ribs 234 are arranged in a plurality of rows extending along the width direction W and spaced apart from each other in the longitudinal direction L. In each row, the number of first notches 236 is equal to the number of flat conductors 120 of the FFC 100. Each first notch 236 is arranged in the width direction W between one of the first directional guide portions 220 and one of the first directional openings 230.

[0020] As shown in Figure 3, the first cable housing 210 has a pair of termination passages 240 that extend through the first cable housing 210 from a first upper surface 212 to a first lower surface 214. The first cable housing 210 has a plurality of projections 242 that extend along the longitudinal direction L to each of the termination passages 240.

[0021] The first cable housing 210 is formed of an insulating material. In the illustrated embodiment, the first cable housing 210 is formed integrally as a single component from the insulating material. In other embodiments, the first cable housing 210 may be assembled from a plurality of separate components so as to form the features of the first cable housing 210 as described in detail above.

[0022] As shown in Figure 4, the second cable housing 250 has a second upper surface 252 and a second lower surface 254 opposite to the second upper surface 252 in the vertical direction V.

[0023] As shown in Figure 4, the second cable housing 250 has a plurality of cable latch arms 256 extending from the second lower surface 254 and extending above the second upper surface 252 in the vertical direction V. The cable latch arms 256 are elastically bendable.

[0024] As shown in Figure 9, the second cable housing 250 has a plurality of second catches 258 extending from the second lower surface 254 in the vertical direction V. The second catches 258 are arranged on a plurality of edges of the second lower surface 254 that are opposite to each other in the width direction W. In the illustrated embodiment, each second catch 258 has a substantially triangular cross-section with a flat surface facing the inside of the second cable housing 250 and an inclined surface facing the outside of the second cable housing 250. In other embodiments, the second catches 258 may have other shapes and structures, as long as they can be releasably fixed to the elements of the contact housing 400, as will be described in detail below.

[0025] As shown in Figure 4, the second cable housing 250 has a plurality of second directional guide portions 260 extending from the second upper surface 252 in the vertical direction V. Each second directional guide portion 260 has a plurality of second curved surfaces 262 at the free end of the second directional guide portion 260 opposite to the second upper surface 252. In the illustrated embodiment, each second directional guide portion 260 is a post having a substantially square cross-section and has four second curved surfaces 262 at its free end. In other embodiments, the second directional guide portion 260 may have other cross-sectional shapes having a different number of second curved surfaces 262 at its free end, and the second directional guide portion 260 has a shape corresponding to the first directional opening 230.

[0026] In the embodiment shown in Figure 4, the second cable housing 250 has a plurality of second directional guides 260 arranged in a plurality of rows. Each of these rows extends along the width direction W and is spaced apart from one another in the longitudinal direction L. In the illustrated embodiment, the second cable housing 250 includes 12 second directional guides 260, with four second directional guides 260 arranged in each of three rows. In other embodiments, the number of rows may be one, two, or more than three, and the second cable housing 250 may have any number of second directional guides 260. The number and arrangement of the second directional guides 260 correspond to the number and arrangement of the first directional openings 230.

[0027] As shown in Figure 4, the second cable housing 250 has a plurality of second alignment walls 266 extending from the second upper surface 252 in the vertical direction V. Each second alignment wall 266 is an elongated member extending along the longitudinal direction L, and in the illustrated embodiment, each second alignment wall 266 is connected to and extends from one of the second directional guides 260. Each second alignment wall 266 has a chamfered surface 268 at the free end opposite the second upper surface 252. In the illustrated embodiment, the number of second alignment walls 266 is less than the number of second directional guides 260, and the second alignment walls 266 extend from only a portion of the second directional guides 260.

[0028] As shown in Figure 4, the second cable housing 250 has a plurality of second directional openings 270 that extend in the vertical direction V to the second upper surface 252. Each second directional opening 270 has a shape corresponding to the shape of the first directional guide portion 220 and is positioned adjacent to one of the second directional guide portions 260. In the illustrated embodiment, the second directional openings 270 are arranged in the same row as the second directional guide portions 260, and are arranged alternately with the second directional guide portions 260 in each row. Since the start and end of each row are one of the second directional guide portions 260, in the illustrated embodiment the number of second directional openings 270 is less than the number of second directional guide portions 260, but in other embodiments the start and end of each row may be one of the second directional openings 270.

[0029] As shown in Figure 4, the second cable housing 250 has a plurality of second alignment recesses 272 extending in the vertical direction V to the second upper surface 252. Each second alignment recess 272 has a shape corresponding to the shape of the first alignment wall 226 and is positioned adjacent to one of the second alignment wall 266. In the illustrated embodiment, each second alignment recess 272 is connected to one of the second directional openings 270 and extends from one of the second directional openings 270 along the longitudinal direction L. In the illustrated embodiment, the number of second alignment recesses 272 is less than the number of second directional openings 270, and the second alignment recesses 272 extend from only a portion of the second directional openings 270.

[0030] As shown in Figure 4, the second cable housing 250 has a plurality of second support ribs 274 extending from the second lower surface 254 in the vertical direction V, and a plurality of second notches 276 are arranged between the second support ribs 274. The second support ribs 274 are arranged in a plurality of rows extending along the width direction W and spaced apart from each other in the longitudinal direction L. In each row, the number of second notches 276 is equal to the number of flat conductors 120 of the FFC 100. Each second notch 276 is arranged in the width direction W between one of the second directional guide portions 260 and one of the second directional openings 270.

[0031] The second cable housing 250 is formed of an insulating material. In the illustrated embodiment, the second cable housing 250 is formed integrally as a single component from the insulating material. In other embodiments, the second cable housing 250 may be assembled from a plurality of separate components so as to form the features of the second cable housing 250 as described in detail above.

[0032] Here, we will explain in more detail how the cable housing 200 is assembled with the FFC100, mainly referring to Figures 5A to 5E.

[0033] The window 150 of the FFC100 is positioned between the first cable housing 210 and the second cable housing 250 in the vertical direction V, and the first cable housing 210 and the second cable housing 250 are separated from each other in the vertical direction V, as shown in Figure 5A. Each of the first directional guides 220 is aligned with one of the second directional openings 270 in the vertical direction V, and each of the second directional guides 260 is aligned with one of the first directional openings 230 in the vertical direction V.

[0034] The flat conductors 120 exposed in window 150 are arranged such that a first surface 122 of each flat conductor 120 faces the first cable housing 210, and a second surface 124 of each flat conductor 120, opposite to the first surface 122, faces the second cable housing 250. Each flat conductor 120 has a first end 126 and a second end 128 opposite to the first end 126, and the first end 126 and the second end 128 are perpendicular to the first surface 122 and the second surface 124. For clarity in the drawings, only one of the flat conductors 120 is indicated by reference number in Figures 5A to 5E, but the description applies equally to each of the flat conductors 120 shown in Figures 5A to 5E.

[0035] In the state of FFC100 shown in Figures 2 and 5A, the flat conductor 120 extends in a single plane across the entire insulating material 110 and the window 150. In the state shown in Figures 2 and 5A, the first surface 122 and the second surface 124 of the flat conductor 120 are parallel to the top and bottom surfaces of the insulating material 110, both in the insulating material 110 and the window 150.

[0036] As shown in Figures 5B and 5C, the first cable housing 210 is gradually moved toward the second cable housing 250 in the vertical direction V and engages with the second cable housing 250. As the first cable housing 210 moves toward the second cable housing 250, each first curved surface 222 of the first directional guide portion 220 contacts each first surface 122 of a pair of flat conductors 120. Each second curved surface 262 of the second directional guide portion 260 contacts each second surface 124 of another pair of flat conductors 120. Due to the arrangement of the first and second directional guide portions 220 and 260, each pair of flat conductors 120 that is contacted by one of the first directional guide portions 220 is also contacted by two second directional guide portions 260, and similarly, each pair of flat conductors 120 that is contacted by one of the second directional guide portions 260 is also contacted by two first directional guide portions 220.

[0037] As shown in Figures 5B and 5C, as the first directional guide portion 220 moves toward the second directional opening 270 and the second directional guide portion 260 moves toward the first directional opening 230, the flat conductor 120 rotates around the longitudinal direction L due to its interaction with the first curved surface 222 and the second curved surface 262. For each of the flat conductors 120, the first curved surface 222 contacts the first surface 122 at one of the first end 126 and the second end 128, and the second curved surface contacts the second surface 124 at the other of the first end 126 and the second end 128. As the directional guide portions 220 and 260 move in opposite directions and contact both ends 126 and 128 of the flat conductor 120, the flat conductor 120 rotates around its center point and around the longitudinal direction L.

[0038] Figures 5D and 5E show the cable housing 200 in the fully mated position M of the first cable housing 210 with the second cable housing 250. In the fully mated position M, the first lower surface 214 abuts against the second upper surface 252. The first directional guide portion 220 is fully inserted into the second directional opening 270, and the second directional guide portion 260 is fully inserted into the first directional opening 230.

[0039] As shown in Figure 5E, the first alignment wall 226 aligns with the second alignment recess 272, and the second alignment wall 266 aligns with the first alignment recess 232. When the first cable housing 210 is fitted with the second cable housing 250, the first alignment wall 226 moves along the vertical direction V to the second alignment recess 272, and the second alignment wall 266 moves along the vertical direction V to the first alignment recess 232. At the fitted position M, the first alignment wall 226 is fully inserted into the second alignment recess 272, and the second alignment wall 266 is fully inserted into the first alignment recess 232. Insertion of the alignment walls 226 and 266 into the corresponding alignment recesses 232 and 272 further ensures that the first cable housing 210 and the second cable housing 250 are aligned along the width direction W and the longitudinal direction L during mating.

[0040] As shown in Figure 5D, in the mating position M, the flat conductor 120 is fully rotated and held by the first directional guide portion 220 and the second directional guide portion 260. Due to the rotation caused by the first curved surface 222 and the second curved surface 262 during mating of the first cable housing 210 with the second cable housing 250, the flat conductor 120 in the mating position M of the cable housing 200 has a rotated portion 140 in the window 150 that is held between the first cable housing 210 and the second cable housing 250. Each of the first directional guide portion 220 and the second directional guide portion 260 provides symmetrical pressing force to rotate the pair of flat conductors 120 on opposite curved surfaces 222, 262, and as a result, the first directional guide portion 220 and the second directional guide portion 260 do not bend or deform in the width direction W during the rotation of the flat conductors 120 or in the mating position M. Thus, the cable housing 200 can more reliably maintain the force necessary to hold the flat conductors 120 in the rotated orientation over time.

[0041] In Figure 2, in each flat portion 130 of the flat conductor 120 in the insulating material 110, the first surface 122 and the second surface 124 remain parallel to the upper and lower surfaces of the insulating material 11. The rotatable portion 140 of the flat conductor 120 has a rotated orientation positioned at an angle to the flat portion 130 extending along a plane defined by the width direction W and the longitudinal direction L. In the embodiment shown in Figure 5D, this angle is approximately 90°, and the rotatable portion 140 has an orientation approximately perpendicular to the flat portion 130. In other embodiments, for example, where the flat conductor 120 has a different width and thickness than the illustrated embodiment, this angle may be between 45° and 90°. In the fully mated state M shown in Figure 5D, each rotatable portion 140 of the flat conductor 120 is exposed in each of the termination holes 240 of the first cable housing 210.

[0042] As shown in Figures 8A and 9, each rotating portion 140 of the flat conductor 120 is held in one of the first notches 236 of the first support rib 234 and one of the second notches 276 of the second support rib 274 in the mating position M of the cable housing 200. In the mating position M, the first support rib 234 is aligned with the second support rib 274 in the vertical direction V. Each first end 126 of the flat conductor 120 in the rotating portion 140 is positioned in one of the first notches 236. Each second end 128 of the flat conductor 120 in the rotating portion 140 is positioned in one of the second notches 276. Positioning the ends 126 and 128 of the flat conductor 120 in the notches 236 and 276 helps to hold the rotating portion 140 in a rotated orientation.

[0043] As shown in Figures 5D and 5E, the first cable housing 210 engages with the second cable housing 250 to secure the cable housing 200 in the mating position M. Each cable latch arm 256 releasably engages with one of the first catches 216 to secure the first cable housing 210 and the second cable housing 250 in the mating position M. In the illustrated embodiment, the cable latch arm 256 bends during mating of the cable housings 210, 250 along the vertical direction V and elastically returns to the position shown in Figures 5D and 5E once the mating position M is reached. In other embodiments, the cable latch arm 256 and the first catches 216 may be other structural elements that releasably engage to secure the first cable housing 210 and the second cable housing 250 in the mating position M.

[0044] One of the terminals 300 of the connector 10 is shown in Figure 6. In Figure 6, the terminal 300 is shown in an undeformed state U. The terminal 300 has a terminal base 310 and an elastic contact portion 320 extending from the terminal base 310. In the embodiment shown in Figure 6, the terminal base 310 is a welding tab 312. In the illustrated embodiment, the welding tab 312 is a flat piece of material configured to be welded to another element, such as a cable conductor. The elastic contact portion 320 has a first beam 330 and a second beam 340.

[0045] As shown in Figure 6, the first beam 330 has an inner surface 332 and an outer surface 334 opposite to the inner surface 332 in the width direction W. The first beam 330 extends from the terminal base 310 to a first end 336 opposite to the terminal base 310 in the vertical direction V. At the first end 336, the first beam 330 is positioned between a pair of first guide arms 339 and has a pair of first contacts 338 adjacent to them. Each of the pair of first contacts 338 is formed by a portion of the first beam 330 that is bent back toward the terminal base 310. Each of the first contacts 338 is formed as an element that protrudes toward the second beam 340 in the width direction W. Each of the first guide arms 339 is bent or spread out in the width direction W away from the second beam 340.

[0046] As shown in Figure 6, the second beam 340 has an inner surface 342 and an outer surface 344 opposite to the inner surface 342 in the width direction W. The second beam 340 extends from the terminal base 310 to a second end 346 opposite to the terminal base 310 in the vertical direction V. At the second end 346, the second beam 340 is positioned between a pair of second guide arms 349 and has a pair of adjacent second contacts 348. Each pair of second contacts 348 is formed by a portion of the second beam 340 that is bent back toward the terminal base 310. Each of the second contacts 348 is formed as an element that protrudes toward the first beam 330 in the width direction W. Each of the second guide arms 349 is bent or spread out in the width direction W away from the first beam 330.

[0047] As shown in Figure 6, the bent portion 350 of the terminal 300 in the elastic contact portion 320 connects the first beam 330 and the second beam 340. The terminal 300 has a support tab 360 that extends from the first beam 330 and abuts against the outer surface 344 of the second beam 340. In the illustrated embodiment, the support tab 360 is an L-shaped element. In other embodiments, the support tab 360 may have any structure that contacts the outer surface 344 of the second beam 340, and alternatively, it may extend from the second beam 340 so as to abut against the outer surface 334 of the first beam 330.

[0048] The first beam 330 and the second beam 340 are elastically bendable relative to each other in the width direction W shown in Figure 6. The support tab 360 restricts the bending of the second beam 340 away from the first beam 330. In the undeformed state U of the terminal 300 shown in Figure 6, the first contact 338 abuts against the second contact 348, and the first beam 330 is separated from the second beam 340. In the undeformed state U, the first guide arm 339 is separated from the second guide arm 349.

[0049] The terminal 300 is formed of a conductive material such as copper or aluminum. In the illustrated embodiment, the terminal 300 is formed integrally as a single component from the conductive material. In other embodiments, the terminal 300 may be assembled from a plurality of separate components so as to form the features of the terminal 300 described in detail above.

[0050] As shown in Figure 7, the contact housing 400 has a housing base 410 having an outer surface 412 and an inner surface 414 opposite to the outer surface 412 in the vertical direction V. The contact housing 400 has a pair of contact latch arms 420 extending from the housing base 410, the contact latch arms 420 extending from the outer surface 412 beyond the inner surface 414 in the vertical direction V. The contact latch arms 420 are elastically bendable relative to the housing base 410.

[0051] As shown in Figure 7, the contact housing 400 has a plurality of terminal passages 430 that extend through the housing base 410 from the outer surface 412 to the inner surface 414 in the vertical direction V. Each of the terminals 300 is positioned and held in one of the terminal passages 430.

[0052] As shown in Figure 7, in each terminal passage 430, the contact housing 400 has a pair of protective walls 440 that demarcate and define a portion of the terminal passage 430. Each protective wall 440 extends vertically V from the inner surface 414 of the housing base 410 and has a rib opening 442 and an end flange 444 at the end opposite to the inner surface 414. The rib opening 442 extends centrally to the end of the protective wall 440, forming a passage that extends through the protective wall 440 in the width direction W. The end flange 444 extends perpendicularly to the protective wall 440 and overlaps with the first contact 338 and second contact 348 of the terminal 300 located in the adjacent terminal passage 430. The end flange 444 does not overlap with the first guide arm 339 or the second guide arm 349 of the terminal 300, which remain exposed along the vertical direction V.

[0053] Here, with reference to Figures 8A to 9, the assembly of the contact housing 400 that holds the terminal 300 with the cable housing 200 at the mating position M around the FFC 100 will be described in more detail.

[0054] The terminals 300 held in the contact housing 400 are inserted into the termination through holes 240 of the first cable housing 210. During insertion, each of the terminals 300 contacts one of the projections 242 in the termination through holes 240. As shown in Figure 8A, each of the projections 242 has a convex body with a tapered end 246 and a flat end 248 opposite to the tapered end 246 in the vertical direction V. As shown in Figure 8A, while inserting the terminals 300 into the termination through holes 240 along the vertical direction V, the first guide arm 339 and the second guide arm 349 first contact the projections 242 near the tapered end 246.

[0055] As shown in Figure 8B, further insertion in the vertical direction V causes the first guide arm 339 and the second guide arm 349 to move along the tapered end 246 of the projection 242, spreading apart in the width direction W. At this intermediate position, the terminal 300 is in a bent state D where the second beam 340 is bent away from the first beam 330 and the first contact 338 is bent away from the second contact 348. The support tab 360 restricts further bending of the second beam 340 and increases the force pushing the second beam 340 against the projection 242 and back towards the first beam 330.

[0056] As terminal 300 is further inserted along the vertical direction V, terminal 300 remains in the bent state D. When terminal 300 reaches the position shown in Figure 8C, the first contact 338 and the second contact 348 first contact the rotating portion 140 of the flat conductor 120. At this position, the first beam 330 and the second beam 340 remain in the bent state D, abutting against the side of the projection 242, and the separated first contact 338 and the second contact 348 align with the flat end 248 of the projection 242. The first contact 338 and the second contact 348 first contact the first end 126 of the flat conductor 120, electrically connecting terminal 300 to the flat conductor 120.

[0057] The terminal 300 in the contact housing 400 is further inserted vertically V into the termination through hole 240 until it reaches the assembled position A of the connector 10 shown in Figures 1 and 9. As shown in Figure 9, at assembled position A, the first beam 330 and the second beam 340 of each elastic contact portion 320 of the terminal 300 extend through the termination through hole 240 and contact the rotating portion 140 of one of the flat conductors 120, thereby electrically connecting the terminal 300 to the flat conductor 120. The first contact 338 and the second contact 348 contact both sides of the rotating portion 140. The first contact 338 and the second contact 348 slide along the surface of the rotating portion 140 from the position shown in Figure 8C to assembled position A shown in Figure 9, where the first contact 338 and the second contact 348 are adjacent to the second end 128 of the flat conductor 120. The sliding of the contacts 338 and 348 along the surface of the flat conductor 120 improves the electrical connection between the terminal 300 and the flat conductor 120.

[0058] The terminals 300 and the contact housing 400 that holds the terminals 300 are fixed in the assembled position A of the connector 10. As shown in Figure 9, in the assembled position A, each contact latch arm 420 is releasably engaged with one of the second catches 258 of the second cable housing 250.

[0059] In the illustrated embodiment, the contact latch arm 420 bends during mating with the contact housing 200 along the vertical direction V, and elastically returns to the position shown in Figure 9 when it reaches the assembled position A. In other embodiments, the contact latch arm 420 and the second catch 258 may be other structural elements that releasably engage to fix the assembled position A.

[0060] As described above, in the embodiments shown in Figures 6 to 9, the terminal base 310 of the terminal 300 is a welding tab 312 configured to be welded to a cable conductor or another conductive element such as a busbar. Other embodiments of the terminal 300 are shown in Figures 10 and 11. Similar reference numerals refer to similar elements, and here we will mainly describe in detail the differences from the embodiment of the terminal 300 shown in Figure 6.

[0061] In embodiments of the terminal 300' shown in Figures 10 and 11, the terminal base 310 connects an elastic contact portion 320, referred to as the first elastic contact portion 320, to a second elastic contact portion 320' which is formed identically to the first elastic contact portion 320, rather than to a weld tab 312. The second elastic contact portion 320' is located at the end of the terminal base 310 opposite to the first elastic contact portion 310. In the embodiment shown in Figure 10, the first elastic contact portion 320 is parallel to the second elastic contact portion 320'. In another embodiment shown in Figure 11, the first elastic contact portion 320 is perpendicular to the second elastic contact portion 320'.

[0062] In the embodiments shown in Figures 10 and 11, the terminals 300' similarly connect to the rotating portion 140 of the flat conductor 120, but instead of electrically connecting the element welded to the welding tab 312 to the flat conductor 120, they allow the rotating portions 140 of the flat conductors 120 of the two FFCs 100 to be connected to each other in various orientations.

Claims

1. A cable housing (200) for a flat flexible cable (100), ● The first cable housing (210) has a first directional guide portion (220) extending from the first lower surface (214) of the first cable housing (210), ● The second cable housing (250) has a second directional opening (270) that extends to a second upper surface (252) of the second cable housing (250), Multiple flat conductors (120) exposed in a window (150) extending through the insulating material (110) of the flat flexible cable (100) are arranged between the first cable housing (210) and the second cable housing (250). When the first directional guide portion (220) moves to the second directional opening (270) and the first cable housing (210) is in the fitted position (M) with the second cable housing (250), the first directional guide portion (220) comes into contact with a pair of flat conductors (120) among the plurality of flat conductors (120), and rotates each of the rotated portions (140) of the flat conductors (120) to the rotated orientation. The rotated orientation of the rotating portion (140) is arranged at an angle to each flat portion (130) of the flat conductor (120) in the insulating material (110). The first cable housing (210) has a plurality of first support ribs (234), and a first notch (236) is provided between the plurality of first support ribs (234). The first end (126) of one of the plurality of flat conductors (120) in the rotating portion (140) is positioned in the first notch (236). Cable housing (200).

2. The first cable housing (210) has a first directional opening (230) extending to the first lower surface (214), and the second cable housing (250) has a second directional guide portion (260) extending from the second upper surface (252). When the second orientation guide portion (260) moves toward the first orientation opening (230), the second orientation guide portion (260) comes into contact with another pair of flat conductors (120) among the plurality of flat conductors (120), and rotates each of the rotating portions (140) of the other pair of flat conductors (120) to the rotated orientation. The cable housing (200) according to claim 1.

3. When the first cable housing (210) is fitted with the second cable housing (250), the first directional guide portion (220) contacts the first surface (122) of one of the plurality of flat conductors (120), and the second directional guide portion (260) contacts the second surface (124) of one of the plurality of flat conductors (120). The cable housing (200) according to claim 2.

4. The first cable housing (210) has a first alignment wall portion (226) extending from the first lower surface (214), The second cable housing (250) has a second alignment recess (272) extending to the second upper surface (252), In the aforementioned fitting position (M), the first alignment wall portion (226) is positioned in the second alignment recess (272). The cable housing (200) according to claim 1.

5. The second cable housing (250) has a plurality of second support ribs (274), and second notches (276) are arranged between the plurality of second support ribs (274). The second support rib (274) is aligned with the first support rib (234) at the fitting position (M), The second end (128) of one of the plurality of flat conductors (120) in the rotating portion (140) is positioned in the second notch (276). The cable housing (200) according to claim 1.

6. A connector (10) for a flat flexible cable (100), ● A cable housing (200) comprising a first cable housing (210) and a second cable housing (250), wherein the first cable housing (210) has a termination through hole (240) extending through the first cable housing (210) and a first directional guide portion (220) extending from a first lower surface (214) of the first cable housing (210), and the second cable housing (250) has a second directional opening (270) extending to a second upper surface (252) of the second cable housing (250), and a flat conductor (120) exposed in a window (150) extending through the insulating material (110) of the flat flexible cable (100) A first directional guide (220) is positioned between the first cable housing (210) and the second cable housing (250), and when the first directional guide (220) moves toward the second directional opening (270) and the first cable housing (210) is in the fitted position (M) with the second cable housing (250), the first directional guide (220) contacts the flat conductor (120), and rotates the rotatable portion (140) of the flat conductor (120) to the rotated orientation, and the rotated orientation of the rotatable portion (140) is positioned at an angle with respect to the flat portion (130) of the flat conductor (120) in the insulating material (110), and the cable housing (200), ● A terminal (300) having an elastic contact portion (320) that extends through the termination through hole (240) and contacts the rotating portion (140) of the flat conductor (120) to electrically connect the terminal (300) to the flat conductor (120), and It is equipped with, The first cable housing (210) has a plurality of first support ribs (234), and a first notch (236) is provided between the plurality of first support ribs (234). The first end (126) of the flat conductor (120) in the rotating portion (140) is positioned in the first notch (236). Connector (10).

7. The second cable housing (250) has a plurality of second support ribs (274), and second notches (276) are arranged between the plurality of second support ribs (274). The second support rib (274) is aligned with the first support rib (234) at the fitting position (M), The second end (128) of the flat conductor (120) in the rotating portion (140) is positioned in the second notch (276). The connector (10) according to claim 6.

8. The elastic contact portion (320) has a first beam (330) and a second beam (340) that is elastically bendable relative to the first beam (330). The first beam (330) and the second beam (340) are in contact with both sides of the rotating portion (140) of the flat conductor (120). The connector (10) according to claim 6.

9. The terminal (300) has a support tab (360) that extends from the first beam (330) and abuts against the outer surface (344) of the second beam (340), The support tab (360) restricts the bending of the second beam (340) in a direction away from the first beam (330). The connector (10) according to claim 8.

10. The first beam (330) has a pair of first contacts (338), and the second beam (340) has a pair of second contacts (348). In the non-deformed state (U) of the terminal (300), the first contact (338) is in contact with the second contact (348), and the first beam (330) is separated from the second beam (340). The connector (10) according to claim 8.

11. The first beam (330) has a pair of first guide arms (339) adjacent to the first contact point (338), and the second beam (340) has a pair of second guide arms (349) adjacent to the second contact point (348), In the non-deformed state (U), the first guide arm (339) is separated from the second guide arm (349). The connector (10) according to claim 10.

12. The first cable housing (210) has a projection (242) that extends to the termination through hole (240), The first guide arm (339) and the second guide arm (349) contact the protrusion (242) during insertion of the terminal (300) into the termination through hole (240), and elastically bend the second beam (340) away from the first beam (330) to a bent state (D) where the first contact (338) is separated from the second contact (348). In the bent state (D), the first contact (338) and the second contact (348) first make contact with the rotating portion (140) of the flat conductor (120). The connector (10) according to claim 11.

13. The device further comprises a contact housing (400) on which the terminals (300) are arranged. In the assembled position (A) where the elastic contact portion (320) contacts the rotating portion (140) of the flat conductor (120), the contact housing (400) is fixed to the cable housing (200). The connector (10) according to claim 6.

14. The elastic contact portion (320) extends from the terminal base portion (310) of the terminal (300), The terminal base (310) is a welding tab (312). The connector (10) according to claim 6.

15. The elastic contact portion (320) is a first elastic contact portion (320) extending from the terminal base portion (310) of the terminal (300), The terminal (300) has a second elastic contact portion (320') at the end of the terminal base portion (310) opposite to the first elastic contact portion (320). The connector (10) according to claim 6.

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