Flat Cable Connector Layout for Stress-Absorbing Terminal Joints
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Solution Overview
Problem
Existing connectors for flat cables experience stress and reduced durability due to displacement caused by clearance between protrusions and holes, leading to potential disconnection under pulling forces.
Innovation Solution
Incorporating an extra length portion in the flat cable design that surrounds protrusions, allowing for absorption of positional deviations and reducing stress on connecting parts, with the option of reinforcing members to enhance rigidity and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protrusion is configured to penetrate through the hole of the flat cable, then the flat cable can be hooked to the protrusion to prevent displacement, but a clearance is formed between the protrusion and hole surface causing the flat cable to be displaced under pulling force
Solution Approach 1:
The patent applies beforehand cushioning by providing an extra length portion in the flat cable that extends beyond the standard arrangement. This extra length acts as a buffer that absorbs the clearance between the protrusion and hole surface, preventing the cable from being pulled out while avoiding excessive stress on the connecting parts. The cushioning is built into the design before assembly, accommodating the manufacturing precision variation without compromising connection reliability.
2Reliability
If the terminal is locked to the housing, then the terminal is securely fixed, but if the flat cable is displaced, stress is generated in the connecting part causing reduction in durability
Solution Approach 1:
The extra length portion serves as a pre-built cushion that absorbs displacement before it reaches the locked terminal connection. This cushioning mechanism protects the durable terminal-housing connection from stress caused by cable movement, allowing the terminal to remain securely fixed while the cable has room to move without generating damaging stress.
Solution Approach 2:
The patent segments the cable structure into a standard length portion and an extra length portion. The standard length portion maintains the locked terminal connection, while the extra length portion independently absorbs displacement. This segmentation allows the terminal fixation and cable positioning functions to be separated, maintaining terminal reliability while protecting connecting part durability.
3Device complexity
If the flat cable is arranged flat on the installation surface, then the connector has a compact structure, but the cable cannot accommodate displacement without generating stress
Solution Approach 1:
The patent extends the solution into another dimension by adding the extra length portion that protrudes from the flat arrangement. Instead of making the entire cable longer, only the extra length portion extends beyond the standard flat arrangement, providing displacement accommodation while maintaining the compact overall structure. This dimensional extension resolves the conflict between simplicity and stress resistance.
Data Source
AI summary
It is aimed to provide a connector capable of suppressing the generation of an excessive stress in a connecting part of a flat cable and a terminal. A connector is provided with a flat cable (60) including a hole (64) serving as a receiving portion, a housing (10) including an installation surface (19) on which the flat cable (60) is arranged and a protrusion (21) projecting from the installation surface (19) and to be inserted into the hole (64), and a terminal (90) to be connected to a conductor (70) of the flat cable (60) and locked to the housing (10). The flat cable (60) includes an extra length portion (66) providing an extra length as compared to flat arrangement on the installation surface (19) in a part surrounding the protrusion (21) or a part arranged between the terminal (90) and the protrusion (21) in an assembled state.