Flat Cable Terminal Assembly With Slotted Dielectric Retention
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Solution Overview
Problem
Existing electrical cable assemblies face challenges in efficiently connecting and retaining multiple conductive wires within a compact, flat configuration, while ensuring reliable mechanical and electrical connections.
Innovation Solution
A method and assembly for a multiconductor flat cable that includes a planar dielectric structure with slots cut between wires, forming wing features, and exposed wire portions. These features are then attached to electrical terminals within a dielectric housing, using triangular prongs to secure the wires and provide a friction fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple conductive wires are arranged in a flat cable configuration, then packaging efficiency is improved, but wire retention and mechanical connection reliability deteriorate
Solution Approach 1:
The flat cable is divided into individual wire channels within the dielectric structure, with each wire having dedicated retention features (wings and slots) that segment the retention mechanism for each conductor, allowing reliable connection while maintaining compact flat geometry
Solution Approach 2:
The terminal features are nested within the dielectric housing structure, with retention wings and slots integrated into the housing itself rather than being separate components, reducing overall assembly complexity while maintaining wire retention functionality
2Ease of manufacture
If traditional connection methods are used for flat cables, then manufacturing simplicity is maintained, but assembly automation and efficiency deteriorate
Solution Approach 1:
The dielectric structure is pre-formed with integrated slots and wing features during the molding process, eliminating the need for post-assembly operations to create retention features, thereby enabling automated assembly while maintaining manufacturing simplicity
Solution Approach 2:
The cable assembly self-retains wires through the integrated wing and slot features that automatically engage when the cable is inserted into the terminal, eliminating the need for separate locking mechanisms or manual retention operations
3Reliability
If locking features are added to the housing to secure terminals, then connection reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The retention functionality is merged into the dielectric structure itself through integrated wings and slots, combining the housing, retention features, and insulation functions into a single molded component, eliminating the need for separate locking features while maintaining connection reliability
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 solution enables easier packaging and automated assembly of electrical cable assemblies, enhances wire retention, and eliminates the need for locking features in the housing, thereby improving the reliability and efficiency of electrical connections.
Implementation Method 1
provide a friction fit
Data Source
Figure 1~2
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AI summary
An electrical cable assembly (10) is presented herein. The electrical cable assembly (10) includes a multiconductor flat cable (12) including a first and second electrically conductive wire (14) arranged in a coplanar fashion with each other and encased within a planar dielectric structure (16). A slot (18) is defined in the planar dielectric structure (16) intermediate the first and second wires (14), thereby forming first wing features (20) in the dielectric structure (16) extending from the first wire (14) and second wing features (20) extending from the second wire (14). Exposed portions of the first and second wires (14) extend beyond the first and second wing features (20). A method (200) of forming the electrical cable assembly (10), an apparatus (100) for forming the electrical cable assembly (10), and an electrical terminal (30) configured for use in the electrical cable assembly (10) is also presented.