Flat Flexible Cable Terminal Crimping Design
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Solution Overview
Problem
Current electrical terminals for flat flexible cables (FFCs) face challenges in achieving reliable, low-resistance connections due to the fragile nature of thin foil conductors, leading to inconsistent electrical connectivity and mechanical unreliability, especially in harsh environments.
Innovation Solution
The terminals feature a crimping portion with a base and foldable sidewalls that include protrusions and serrations, allowing for secure crimping of the conductor within an aperture, preventing damage and ensuring reliable electrical contact by distributing force evenly and engaging the conductor effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If piercing-style crimp terminals are used to establish electrical connection with the embedded conductor, then connection can be made through insulation and adhesive material, but electrical resistance increases and connectivity becomes inconsistent
Solution Approach 1:
The terminal design extracts the conductor from within the insulation and adhesive material by creating an opening that exposes the conductor, allowing direct contact without piercing through multiple layers. This extraction approach eliminates the high resistance and inconsistency problems associated with piercing-style connections.
Solution Approach 2:
The terminal performs preliminary action by pre-forming an opening in the insulation material and positioning the conductor before the crimping operation. This preliminary exposure of the conductor allows for consistent, low-resistance electrical contact from the start, rather than relying on piercing action during termination.
2Ease of operation
If piercing-style crimp terminals are used to establish electrical connection, then connection can be made through insulation material, but mechanical unreliability increases over time in harsh environments
Solution Approach 1:
The terminal extracts the conductor from the insulation material by forming an opening that exposes the conductor, allowing direct mechanical contact. This extraction eliminates the mechanical unreliability of piercing-style connections where the terminal must maintain force through insulation and adhesive layers over time in harsh environments.
Solution Approach 2:
The terminal performs preliminary action by pre-forming an opening and exposing the conductor before crimping, establishing a direct mechanical bond that is inherently more reliable over time compared to piercing through multiple material layers.
3Weight of moving object
If thin foil conductor material is used in FFC, then lower profile and lighter weight are achieved, but conductor fragility increases leading to higher electrical resistance and inconsistent connectivity
Solution Approach 1:
The terminal performs preliminary action by pre-forming an opening in the insulation material and positioning the thin foil conductor before crimping. This preliminary setup protects the fragile conductor during assembly and ensures consistent, low-resistance electrical contact without subjecting it to the stresses of piercing through multiple material layers.
Solution Approach 2:
The terminal design applies local quality by creating a specific opening geometry and crimping configuration tailored to the thin foil conductor's characteristics. This localized adaptation ensures the fragile conductor receives appropriate support and contact pressure only where needed, maintaining electrical reliability despite the conductor's inherent fragility.
4Reliability
If conventional round wire F-crimps are used as reference, then low electrical resistance is achieved, but adaptation to FFC geometry and embedded conductors becomes difficult
Solution Approach 1:
The terminal design applies local quality by creating a specific opening geometry and crimping configuration tailored to the FFC's flat geometry and embedded conductor structure. This localized adaptation allows the terminal to achieve low electrical resistance similar to round wire F-crimps while being specifically suited to FFC characteristics.
Solution Approach 2:
The terminal performs preliminary action by pre-forming an opening that accommodates the FFC's specific geometry and conductor positioning before crimping. This preliminary configuration enables the terminal to adapt to FFC characteristics while maintaining the low electrical resistance performance associated with conventional crimping techniques.
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
This design enables reliable, low-resistance connections with reduced risk of conductor damage, ensuring consistent electrical contact and mechanical reliability even in harsh conditions.
Implementation Method 1
The sidewalls are foldable into the opening for crimping the conductor within the opening
Implementation Method 2
the conductor is pressed into the aperture formed through the base by the sidewall protrusion
Data Source
AI summary
A cable assembly includes a flat flexible cable having a plurality of conductors embedded within an insulation material. A portion of each of the conductors is exposed via openings selectively formed in the insulation material, allowing for a crimping portion of an electrically conductive terminal to engage with the conductor within the opening. The crimping portion of the terminal includes a base defining at least one aperture formed therethrough, and first and second sidewalls extending from the base. The base and sidewalls define a conductor opening configured to receive the conductor therein. At least one of the first of second sidewalls includes a sidewall protrusion extending therefrom, wherein the sidewalls are foldable into the conductor opening for crimping the conductor therewithin. In a crimped state of the crimping portion, the conductor is pressed into the aperture by the sidewall protrusion.