Crimped Spring Connector for Flexible Flat Cable Locking
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Solution Overview
Problem
Conventional electrical terminals with crimped connections are not compatible with flexible flat cables, making it difficult to establish a reliable electrical connection.
Innovation Solution
An electrical connector design featuring a terminal cavity with a contact area and a connection area, along with movable hooks and a block that latches into position, allowing for secure engagement with flexible flat cables and electrical terminals with deformed crimp wings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimped connections are used to attach electrical terminals to wires, then a strong mechanical connection is achieved, but compatibility with flexible flat cables is lost
Solution Approach 1:
The electrical terminal is designed with differentiated crimp wings having distinct geometries and functions. The first crimp wings are configured for engaging conductors while the second crimp wings are specifically shaped to engage the flat cable insulator, allowing each part to have optimized local properties for its specific function.
Solution Approach 2:
The crimp connection is divided into multiple functional segments: first crimp wings for conductor engagement, second crimp wings for insulator engagement, and a flat cable engagement portion with specific geometry for flat cable compatibility. This segmentation allows each segment to be optimized independently for its specific purpose.
2Reliability
If a secure mechanical connection is established between the electrical terminal and flexible flat cable, then reliability is improved, but the device complexity increases due to additional components like hooks and block
Solution Approach 1:
The hooks and block are integrated as part of the electrical terminal structure rather than being separate components. The flat cable engagement portion is merged with the crimp wings to form a unified structure that provides both mechanical securing and electrical connection functions.
Solution Approach 2:
The electrical terminal structure includes self-securing features where the hooks and block work together to automatically secure the flexible flat cable in place during the crimping process, eliminating the need for additional separate securing mechanisms.
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
The electrical connector effectively secures flexible flat cables to electrical terminals, maintaining a reliable electrical connection and mechanical stability through the spring force applied by the stressed insulator wings.
Implementation Method 1
The electrical terminal includes a first set of crimp wings that are deformed to engage an inner conductor on the wire to provide an electrical connection. A second set of crimp wings are also deformed to engage an outer insulator on the wire to provide a stronger mechanical connection.
Implementation Method 2
When the block is in the latched position, the crimp wings are in a stressed position and the electrical terminal applies a spring force against the block.
Data Source
AI summary
An electrical connector includes a body with a terminal cavity that defines a terminal axis. The terminal cavity is adapted to accommodate an electrical terminal and has a contact area that includes a terminal lock. The terminal cavity also has a connection area that is open in a block direction that is perpendicular to the terminal axis. The electrical connector includes a block that is movable relative to the body to a latched position, and when the block is in the latched position it is located in the block direction from the connection area.