Flat Cable Connector Assembly for Precise Terminal Alignment
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Solution Overview
Problem
The existing methods for securing a flat cable to a conductive element face challenges in achieving reliable and efficient electrical connections, particularly due to alignment issues between the terminal and the flat cable, which can result in reduced contact area and inefficient electrical conduction.
Innovation Solution
A connector assembly is designed with a connector housing, a terminal, and a stuffer, where the stuffer engages the terminal to urge it toward a planar surface, ensuring proper alignment and intimate contact with the flat cable, and a welding element is used to secure the conductive regions through an aperture, facilitating automated assembly and enhanced electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods are used to connect flat cable to terminal, then the connection can be made, but the alignment is poor and contact area is reduced
Solution Approach 1:
The planar surface is pre-formed on the flat cable contact region before terminal insertion. This preliminary preparation ensures that when the terminal is inserted and urged by the stuffer, the contact regions are already positioned for optimal alignment, eliminating the need for complex real-time alignment mechanisms during assembly.
Solution Approach 2:
The stuffer acts as an intermediary component between the terminal and the planar surface. It transfers and distributes the urging force uniformly across the terminal, ensuring consistent contact pressure and alignment. The stuffer mediates the interaction between the terminal's conductive member and the flat cable's contact region, achieving reliable electrical connection.
2Productivity
If manual alignment methods are used, then connection can be made, but automation is difficult and productivity is low
Solution Approach 1:
The planar surface on the flat cable enables self-alignment during the insertion process. As the terminal is inserted into the connector housing, the planar surface automatically guides and positions the flat cable contact region against the terminal's conductive member, eliminating the need for external alignment mechanisms or manual intervention. This self-aligning feature makes the process easily automatable.
Solution Approach 2:
By pre-forming the planar surface on the flat cable, the alignment function is built into the component itself beforehand. This preliminary structural preparation allows automated insertion mechanisms to simply place the components together without requiring complex alignment algorithms or mechanisms, significantly improving automation capability and productivity.
3Reliability
If terminal is not properly urged toward flat cable, then assembly is easier, but contact area is reduced and connection is unreliable
Solution Approach 1:
The stuffer serves as a dedicated intermediary component whose sole function is to urge the terminal toward the flat cable's planar surface. This specialized component simplifies the overall connector structure by separating the alignment and contact functions from the terminal and housing, while ensuring reliable electrical connection through controlled mechanical pressure.
Solution Approach 2:
The connector assembly is segmented into distinct functional components: the planar surface on the flat cable for alignment, the stuffer for applying contact force, and the terminal for electrical connection. This segmentation allows each component to be optimized for its specific function, achieving reliable connection without overly complicating any single component.
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 ensures reliable and efficient electrical connections by ensuring proper alignment and increased contact area between the terminal and the flat cable, improving the durability and manufacturing efficiency of the electrical connector assembly.
Implementation Method 1
The first conductive contact region of the flat cable is welded to the second conductive contact region of the terminal through the aperture of the connector housing
Data Source
AI summary
A connector assembly includes a connector housing. The connector housing includes a first side having a first opening. The first opening includes a first planar surface within the connector housing. The connector housing includes a second side having a second opening. The connector assembly includes a terminal with an attachment portion and a conductive member. The conductive member includes a tanged portion. The attachment portion includes a socket opening accessible through the second opening of the connector housing. The connector assembly includes a stuffer insertable into the first opening of the connector housing. The tanged portion of the terminal is engageable with the stuffer to urge the conductive member toward the first planar surface.