Flat Flexible Cable Connector With Elastic Contact

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Solution Overview

Problem

Flat flexible cables (FFCs) face challenges in achieving quick, robust, and low resistance termination techniques for mating with existing components in harsh environments, due to issues like plastic creep and stress relaxation leading to inconsistent electrical connectivity and mechanical unreliability.

Innovation Solution

A connector system featuring a cable housing with an elastic portion that elastically bears against the flat conductor to establish a secure electrical connection, using a housing structure with orientation guides and alignment posts to securely position the conductor and ensure reliable contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If piercing-style crimp terminals are used to establish electrical connection with the embedded conductor, then the connector can be manufactured with simple structure, but the electrical connectivity becomes inconsistent and mechanical reliability deteriorates over time due to plastic creep and stress relaxation

Engineering Contradiction:

Improveconnector manufacturing simplicityVSAvoidelectrical connectivity consistency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of piercing the conductor through insulation (conventional approach), the patent inverts the approach by having the conductor pierce through the insulation to contact the terminal directly. The sharp edge of the conductor pierces the insulation material to establish direct contact with the terminal contact, eliminating the need for complex piercing terminals while improving reliability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the mechanical parameters of the terminal by using a cup-shaped terminal with a flexible contact that can deform elastically. This allows the terminal to accommodate variations in conductor position and dimensions while maintaining consistent electrical contact, resolving the reliability issue without complicating manufacturing.

Inventive Principle:

Principle #35Parameter changes

2Strength

If piercing-style crimp terminals are used to establish electrical connection, then the initial connection can be made, but plastic creep and stress relaxation cause mechanical unreliability over time

Engineering Contradiction:

Improveinitial connection strengthVSAvoidconnection durability over time

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent inverts the piercing action from terminal-to-conductor to conductor-to-terminal. The sharp edge of the conductor pierces the insulation and makes direct contact with the terminal, creating a more stable mechanical connection that resists creep and relaxation over time.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The cup-shaped terminal with its flexible contact provides a cushioning effect that compensates for dimensional variations and stress changes over time. The elastic deformation capability of the terminal contact absorbs mechanical stresses before they can cause failure, ensuring long-term durability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If conventional termination techniques are used, then the connector can be assembled quickly, but the electrical connection resistance increases and connectivity becomes inconsistent

Engineering Contradiction:

Improvetermination speedVSAvoidelectrical connectivity consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent segments the termination process into distinct functional elements: the insulation piercing function, the conductor contact function, and the terminal mounting function. This segmentation allows each element to be optimized independently, achieving both quick assembly and consistent electrical connectivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the geometric parameters of the terminal contact to optimize electrical connectivity. The cup-shaped design with specific dimensional relationships ensures low contact resistance and consistent electrical connection while maintaining simple manufacturing and quick assembly.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a stable and reliable electrical connection by eliminating the need for piercing-style terminals, reducing mechanical stress and enhancing durability in harsh conditions.

Implementation Method 1

The elastic portion extends through the termination passage and elastically bears against the flat conductor to electrically connect the contact to the flat conductor

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11296446B2Connector for a flat flexible cable

Publication Date: 2022.04.05 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A connector for a flat flexible cable includes a cable housing and a contact having an elastic portion. The cable housing includes a first housing having a termination passage extending through the first housing and a second housing mated with the first housing. A flat conductor exposed in a window extending through an insulation material of the flat flexible cable is held between the first housing and the second housing. The elastic portion extends through the termination passage and elastically bears against the flat conductor to electrically connect the contact to the flat conductor.