Flexible Circuit Connector With Wiping Contacts for Robotic Assembly
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Solution Overview
Problem
Automotive electrical wiring harnesses using flexible circuit configurations face challenges in automated/robotic installation due to difficulties in connecting to other terminals, leading to increased costs and manual labor requirements.
Innovation Solution
An electrical connector system featuring a connector housing with tin-coated terminals and a flexible circuit with exposed conductive traces, combined with a rigid stiffener device and a spring-loaded cover assembly that enables a lateral wiping action for secure electrical connection, facilitating automated robotic assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If flexible circuit configurations are used to replace round wire configurations, then weight is reduced and packaging size is reduced, but automated/robotic installation becomes difficult
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and geometry of the flexible circuit connector. It introduces a stiffener that changes the FC's rigidity parameter locally at the connector region, and designs a specific engagement geometry with guide pins and recesses that enables automated robotic installation while maintaining the overall flexibility benefits of the FC configuration.
2Volume of moving object
If flexible circuit configurations are used to replace round wire configurations, then packaging size is reduced, but automated/robotic installation becomes difficult
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and geometry of the flexible circuit connector. It introduces a stiffener that changes the FC's rigidity parameter locally at the connector region, and designs a specific engagement geometry with guide pins and recesses that enables automated robotic installation while maintaining the overall flexibility benefits of the FC configuration.
3Extent of automation
If conventional round wire configurations are used, then automated installation is easier, but weight increases and packaging size increases
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and geometry of the flexible circuit connector. It introduces a stiffener that changes the FC's rigidity parameter locally at the connector region, and designs a specific engagement geometry with guide pins and recesses that enables automated robotic installation while maintaining the overall flexibility benefits of the FC configuration.
4Extent of automation
If conventional round wire configurations are used, then automated installation is easier, but packaging size increases
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and geometry of the flexible circuit connector. It introduces a stiffener that changes the FC's rigidity parameter locally at the connector region, and designs a specific engagement geometry with guide pins and recesses that enables automated robotic installation while maintaining the overall flexibility benefits of the FC configuration.
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 system achieves reliable, low-cost electrical connections with reduced manual assembly labor and automated installation capabilities, enhancing efficiency and cost-effectiveness while maintaining the benefits of flexible circuit configurations such as weight reduction and improved packaging.
Implementation Method 1
a spring device and a spring retainer cover arranged on an opposing side of the FC that, when engaged with/connected to the rigid stiffener device, provides securing and downward force on the FC
Implementation Method 2
a tin-coating has been applied
Data Source
AI summary
Electrical connector systems and methods create an electrical connection between a flexible circuit (FC) and a metal terminal of another connector. A reliable electrical connection is achieved with a low-cost tin contact plating, by an automatic FC to metal terminal wiping action with contact force, during the connector to FC assembly process. The connector to FC assembly process is also well suited for automated robotic assembly, which can save costs compared to manual assembly/installation.