FFC Terminal Structured Dimples for Low-Resistance Contact
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Solution Overview
Problem
Current electrical connections for flat flexible cables are prone to high resistance and contamination issues due to reliance on displacement crimping or welding, which require costly tooling and can lead to reduced performance over time and single-point contact risks.
Innovation Solution
A conductive terminal with staggered protruding elements on its contact surfaces provides multiple points of contact, maintaining low resistance and preventing contamination, and optional inversion with welding enhances mechanical engagement and strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If displacement crimping or welding processes are used for FFC connections, then robust electrical connections are achieved, but significant tooling and fixturing costs are required
Solution Approach 1:
The patent replaces complex mechanical displacement crimping systems with a simpler mechanical insertion and retention system. The tapered guide surfaces and resilient retention members provide automatic alignment and secure retention without requiring expensive displacement crimping tooling or fixturing, while maintaining reliable electrical connections through the conductive contact surfaces.
2Ease of manufacture
If non-displacement crimping processes are used, then tooling costs are reduced, but electrical performance degrades over time due to creep and relaxation of insulation
Solution Approach 1:
The patent incorporates preliminary alignment features in the form of tapered guide surfaces that automatically align the FFC with the terminal contacts during insertion. This preliminary alignment action ensures proper positioning before the retention members engage, preventing misalignment that could lead to creep and relaxation issues over time, while still using a simple non-displacement crimping process.
3Device complexity
If a single point of contact is used in the mating area, then the structure is simple, but contamination from dust particles or other contaminants can disrupt the connection
Solution Approach 1:
The patent divides the contact interface into multiple contact points through the use of multiple conductive contact surfaces and retention members. This segmentation ensures that if one contact point becomes contaminated, other contact points maintain the electrical connection, thereby improving reliability without significantly increasing structural complexity.
Data Source
AI summary
A conductive terminal for a flat flexible cable comprises a first contact surface, and a second contact surface opposing the first contact surface. The first and second contact surfaces define a space therebetween for receiving a flat flexible cable along a longitudinal direction of the terminal. A structure of protruding elements is defined on the first contact surface and includes a plurality of protruding elements extending from the first contact surface in a direction of the second contact surface. The structure of protruding elements includes at least one protruding element having a first height, and at least one protruding element having a second height, distinct from the first height.