Flat Flexible Cable Terminal Crimping with Fold Guide
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Solution Overview
Problem
Existing electrical terminals for flat flexible cables lack an effective method for secure attachment, leading to potential disconnection and instability in electronic devices with dense electronics.
Innovation Solution
A method involving crimping an electrical terminal onto a flat flexible cable by deforming first and second crimp wings to engage multiple layers of the cable, using a crimp tool with a fold guide and cable guide to ensure secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electrical terminal is used with a flat flexible cable, then the device structure remains simple, but the connection stability is poor leading to potential disconnection
Solution Approach 1:
The terminal is divided into multiple functional segments: a body portion for receiving the cable, first crimp wings for engaging the cable body, and second crimp wings for engaging the stripped portion. This segmentation allows each component to perform its specific function independently, achieving reliable connection while maintaining manufacturing simplicity
Solution Approach 2:
The terminal engagement mechanism transitions from simple linear pressing to multi-dimensional crimping. The first and second crimp wings engage the cable in different spatial dimensions and orientations, creating a three-dimensional secure attachment that prevents disconnection from multiple directions
2Strength
If the conductor is pressed into engagement with the terminal, then the manufacturing process remains simple, but the connection strength is insufficient
Solution Approach 1:
The terminal is pre-formed with crimp wings in specific orientations and positions before the crimping operation. The fold guide and cable guide are pre-positioned in the crimping tool to ensure proper cable alignment and bending during the crimping process, eliminating the need for complex real-time adjustments and enhancing both connection strength and manufacturing efficiency
Solution Approach 2:
The fold guide acts as an intermediary element between the crimping tool and the cable. It controls the bending of the cable during crimping, ensuring that the stripped portion is properly positioned and oriented for engagement with the second crimp wings, thereby achieving strong connection without complex manual manipulation
3Reliability
If a secure attachment method is implemented, then the connection reliability improves, but the cable management complexity increases
Solution Approach 1:
The crimping tool with integrated fold guide and cable guide enables the cable to self-align and self-bend into the correct position during the crimping process. The guides automatically position the cable and control its deformation, eliminating the need for complex external cable management systems or manual positioning steps
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 method provides a strong and stable connection between the electrical terminal and the flat flexible cable, preventing easy disconnection and enhancing cable management in densely electronic devices.
Implementation Method 1
deforming crimp wings on an electrical terminal to engage a flat flexible cable
Implementation Method 2
deforming the first crimp wings to engage one layer of the flat flexible cable, bending the flat flexible cable over the first crimp wings, and deforming the second crimp wings to engage two layers of the flat flexible cable
Data Source
AI summary
A method of attaching an electrical terminal to a flat flexible cable includes the step of deforming crimp wings on an electrical terminal to engage a flat flexible cable.