FFC Connector Assembly With Sliding Holder and Multi-Tine Termination
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Solution Overview
Problem
The implementation of flat flexible cables (FFCs) in complex and high-volume applications is hindered by the need for quick, robust, and low resistance termination techniques to facilitate reliable mating with components like printed circuit boards (PCBs).
Innovation Solution
A connector assembly featuring a terminal holder with sharpened tines and a cable holder that slides between insertion and installed positions, allowing for secure electrical contact between FFC conductors and substrate terminals, ensuring strong mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional termination techniques are used for FFC, then manufacturing cost and time are reduced, but connection reliability and electrical performance deteriorate
Solution Approach 1:
The terminal is divided into multiple independent tines (at least two tines per terminal) that can penetrate the FFC conductor separately. This segmentation allows each tine to make individual contact points with the conductor, improving connection reliability while maintaining a compact terminal structure that is easy to manufacture.
Solution Approach 2:
The tines are pre-formed with sharpened tips during terminal manufacturing, preparing them in advance for effective conductor penetration. The cable holder is also pre-configured with positioning features that guide the FFC conductors into proper alignment with the terminals before the crimping operation, ensuring reliable contact without requiring complex alignment procedures during assembly.
2Reliability
If sharp tines are used to penetrate FFC conductors, then electrical contact quality improves, but manufacturing precision requirements increase
Solution Approach 1:
Each terminal is segmented into multiple tines rather than using a single solid contact element. This segmentation distributes the electrical contact function across multiple sharper, thinner elements that can more easily penetrate the FFC conductor with lower force requirements, reducing the precision needed for the overall terminal while maintaining high contact quality.
Solution Approach 2:
The terminal contact elements are designed with sharpened tips that change the geometric parameters of the contact interface. The sharp geometry concentrates force on a smaller area, enabling effective conductor penetration with lower crimping forces and reduced precision requirements for the crimping process itself.
3Strength
If multiple tines per terminal are used, then connection robustness improves, but terminal complexity increases
Solution Approach 1:
The terminal is segmented into multiple tines integrated within a single terminal body, providing multiple contact points and improved connection robustness. Despite the multiple contact elements, the tines are formed as an integrated structure within the terminal housing, maintaining manufacturing simplicity and avoiding excessive complexity.
Solution Approach 2:
Multiple tines are merged into a single integrated terminal structure rather than using separate components. This combining approach provides the mechanical strength and contact reliability of multiple contacts while maintaining the simplicity of a single terminal piece that can be manufactured and handled as one unit.
Data Source
AI summary
A connector for a flat flexible cable (FFC) has a terminal holder adapted to be mounted to a substrate, and a plurality of terminals arranged within the terminal holder. Each terminal defines a plurality of sharpened tines arranged in a row. A cable holder is slidably arranged on the terminal holder and movable between an insertion position wherein an FFC is free to be inserted into the cable holder, and an installed position wherein the tines of each terminal engage with or penetrate conductors of the FFC arranged within the cable holder for establishing electrical contact therewith.