Crimp-Mounted Electrical Terminals for Flat Flex Cables
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Solution Overview
Problem
Conventional electrical connectors face challenges in securely and efficiently connecting flat flex cables to electrical terminals, particularly in maintaining a reliable connection under stress and vibration, while also requiring reduced crimp forces to prevent damage to the connector housing.
Innovation Solution
The electrical terminal design incorporates a crimp member with flexible crimp teeth that pierce through the flat flex cable and fold back to secure it, providing a robust connection while minimizing crimp forces, and includes a strain relief assembly to manage stress and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimping methods are used to connect flat flex cables to electrical terminals, then the connection can be secured, but high crimp forces are required that may damage the connector housing
Solution Approach 1:
The crimp member geometry is changed to include angled surfaces and tooth configurations that convert vertical crimping force into radial clamping force, reducing the peak force required and distributing it more effectively to prevent housing damage while maintaining secure cable attachment
Solution Approach 2:
The crimp member acts as an intermediary between the compression tool and the flat flex cable, featuring a jaw structure with teeth that grip the cable and angled surfaces that transfer force to the housing, thereby mediating the force transmission to reduce direct impact on the housing
2Reliability
If secure connection under stress and vibration is achieved, then connection reliability improves, but the crimp forces required increase which may damage the housing
Solution Approach 1:
The crimp member features curved or angled surfaces rather than flat surfaces, allowing for more efficient force distribution and stress dispersion during crimping and under subsequent vibration loads, maintaining reliability while reducing peak forces that could damage the housing
Solution Approach 2:
The crimp member design allows for dynamic force distribution through its angled surfaces and tooth structure, adapting to the cable material properties and providing progressive engagement that secures the connection under vibration while minimizing initial crimp forces on the housing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures a reliable and durable connection between the electrical terminals and flat flex cables, maintaining integrity under stress and vibration while reducing the risk of damage to the connector housing.
Implementation Method 1
The crimp member has flexible crimp teeth configured to pierce through a flat flex cable along a first direction, and further configured to fold back and pierce into the flat flex cable along a second direction substantially opposite the first direction when crimped
Data Source
AI summary
In accordance with one embodiment, an electrical connector includes a connector housing, and at least one electrical terminal supported by the connector housing. The electrical terminal defines a mating portion and a mounting portion, the mounting portion carrying a crimp member having crimp teeth configured to pierce through a flex cable when crimped so as to mount the flat flex cable to the mounting portion of the electrical terminal.