Flat Flexible Cable Connector With Protrusion Strain Relief
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Solution Overview
Problem
Flat flexible cables (FFCs) in connectors are prone to straining and disconnection due to external forces, leading to impaired electrical and mechanical connections, reducing the reliability of the connector system.
Innovation Solution
A connector design featuring a housing with a movable cover and protrusions that secure the FFC in place, providing strain relief by abutting the base when closed, and using crimping wings and latching arms to mechanically and electrically connect the terminals to the FFC, ensuring a secure fit even under force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the FFC is retained only by mechanical connection to terminals, then the connector structure is simple, but the FFC is prone to straining and disconnection under external forces
Solution Approach 1:
The housing is divided into a base and a separate cover that can move between open and closed positions. The cover contains protrusions that independently secure the FFC, while the base contains the terminals. This segmentation allows the FFC to be retained by both the cover (mechanical retention) and the terminals (electrical connection), improving reliability without requiring a completely complex integrated structure.
Solution Approach 2:
The cover is designed with protrusions that preliminarily secure the FFC in place before final assembly. When the cover is closed, the protrusions extend through openings in the FFC and abut the base, pre-positioning and stabilizing the FFC to prevent straining and disconnection during use.
2Reliability
If the FFC is secured with additional retention features, then the FFC retention is improved, but the manufacturing complexity increases
Solution Approach 1:
The FFC retention function is merged into the cover structure itself through the protrusions. The protrusions are integrated features of the cover that perform both structural support and FFC retention functions simultaneously. This merging eliminates the need for separate retention components, improving FFC retention while maintaining ease of manufacture.
Solution Approach 2:
The cover serves multiple functions: it provides structural enclosure, contains the protrusions for FFC retention, and works with the base to secure the FFC. The protrusions themselves serve dual purposes by both retaining the FFC mechanically and positioning it for proper electrical connection. This multi-functionality improves retention without adding separate manufacturing steps.
3Reliability
If the cover is made fixed, then the FFC is more securely retained, but the ease of assembly and disassembly is reduced
Solution Approach 1:
The cover is designed as a dynamic component that can move between open and closed positions rather than being fixed. This dynamic design allows the connector to be easily assembled and disassembled by opening the cover, while when closed, the protrusions provide secure retention of the FFC. The dynamic nature resolves the contradiction between secure retention and ease of operation.
Data Source
AI summary
A connector includes a housing and a flat flexible cable disposed in the housing. The housing has a base and a cover movable with respect to the base between an open position and a closed position. The cover has a body and a protrusion protruding from the body. The flat flexible cable has an insulation material and a plurality of flat flexible conductors embedded in the insulation material. The flat flexible cable has an opening extending through the insulation material. The protrusion extends through the opening and abuts the base in the closed position of the cover.