Tray-Based Flat Cable Assembly for Variable Conductor Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical assemblies for vehicles face challenges in securely connecting and restraining flat cables, particularly when dealing with cables of varying conductor widths and configurations.
Innovation Solution
The electrical assembly comprises a housing, a tray, and terminal subassemblies, where the tray includes slots and a cavity to house the flat cable and terminal subassemblies. The assembly uses subassembly conductors with offset planar portions to align with varying conductor widths, ensuring secure electrical connections and mechanical restraint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional electrical assembly design is used, then the structure is simple, but the flat cable cannot be securely restrained when dealing with cables of varying conductor widths and configurations
Solution Approach 1:
The electrical assembly is divided into distinct functional modules: a housing, a tray partially disposed within the housing, terminal subassemblies, and a flat cable. The tray is further segmented into slots and a cavity to separately accommodate different portions of the cable and terminals, allowing each segment to perform its specific function while contributing to overall cable restraint reliability.
Solution Approach 2:
The tray is nested within the housing, creating a hierarchical structure where the tray's slots and cavity are positioned to receive and restrain the flat cable and terminal subassemblies. This nested arrangement allows the cable to be securely held within the housing while maintaining structural organization and facilitating assembly.
2Adaptability or versatility
If subassembly conductors with offset planar portions are used, then alignment with varying conductor widths is achieved, but manufacturing complexity increases
Solution Approach 1:
The subassembly conductors feature offset planar portions at specific locations to align with varying conductor widths of the flat cable. This local modification to the conductor structure provides the necessary adaptability for different cable configurations while maintaining the simplicity of the overall manufacturing process. The offset portions are strategically positioned to engage with corresponding features on the tray or housing, ensuring proper alignment without requiring complex manufacturing techniques.
Data Source
AI summary
The present application relates to an electrical assembly. An assembly includes a housing, a tray, a flat cable, and a terminal subassembly. The tray may be partially disposed within the housing and may include a slot and a cavity. The tray may be formed separately from the housing. The flat cable may include an electrical conductor with an exposed portion. The terminal subassembly may include a first terminal connected to a first end of a subassembly conductor and a second terminal connected to a second end of the subassembly conductor. A portion of the flat cable may be disposed in the cavity. A first portion of the terminal subassembly may be disposed in the slot and a second portion of the terminal subassembly may be disposed in the cavity. The second terminal may be electrically connected to the exposed electrical conductor.