Flat Cable Connector Assembly for Easier Vehicle Harness Routing
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Solution Overview
Problem
Existing electrical connection systems in vehicles face challenges in ease of assembly and routing, particularly with the transition from traditional round wire harnesses to flat wire harnesses, necessitating improved assembly methods for flat wire harnesses.
Innovation Solution
A method involving the steps of inserting an insulated flexible flat cable into a connector and terminal housing, attaching electrical terminals to conductors, and pulling the cable to draw terminals and housing into place, using unfolded sheet metal terminals and a terminal cap with protrusions for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional round wire harnesses are used, then assembly is simpler with conventional methods, but routing in vehicles becomes more difficult and space-consuming
Solution Approach 1:
The patent transitions from traditional round wire harnesses to a flat cable architecture, fundamentally changing the dimensional configuration from cylindrical to planar. This dimensional change enables superior routing capabilities in vehicle applications by allowing the harness to conform to flat surfaces and optimize space utilization, directly addressing the routing ease improvement while managing the structural complexity through standardized flat cable construction
2Ease of operation
If flat wire harnesses are adopted, then routing improves and space is optimized, but assembly complexity increases
Solution Approach 1:
The patent divides the flat cable assembly into distinct functional segments: conductor elements, insulation layers, and terminal sections. This segmentation allows each component to be manufactured and prepared separately, then assembled in a systematic manner that reduces overall assembly complexity despite the innovative flat architecture
Solution Approach 2:
The patent incorporates pre-attached terminals and pre-configured conductor arrangements within the flat cable structure before final assembly. This preliminary preparation of components simplifies the final assembly process by reducing the number of steps required to create functional electrical connections, thereby improving ease of manufacture
3Ease of manufacture
If insulation is removed from conductors, then terminal attachment is enabled, but exposure of conductors increases assembly steps
Solution Approach 1:
The patent performs insulation removal and conductor preparation as preliminary steps before terminal attachment. By pre-exposing the conductors and preparing them for connection, the actual terminal attachment process is simplified and enabled, making the manufacturing process more efficient despite the additional preparation steps
4Reliability
If terminals are drawn into housing cavities, then secure connection is achieved, but assembly process becomes more complex
Solution Approach 1:
The patent employs a nested assembly structure where terminals are inserted into cavities within the housing, and the flat cable is routed through and around these components. This nesting arrangement achieves secure mechanical and electrical connections while organizing the assembly process into logical sequential steps, managing the complexity through structured nesting rather than random component placement
Data Source
AI summary
A method of assembling an electrical connector includes the steps of providing an insulated flexible flat cable having a plurality of electrical conductors, inserting the flat cable within a connector housing, inserting the flat cable within a terminal housing, attaching a plurality of electrical terminals to the plurality of electrical conductors, pulling the flat cable to draw the plurality of electrical terminals within a plurality of terminal cavities defined in the terminal housing, and pulling the flat cable to further draw the terminal housing within the connector housing. An electrical connector assembly which may be made by this method is also disclosed.