Flexible Printed Circuit Harness with Encapsulated Connector
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, and difficult to manipulate due to their complex assembly of insulated wires and cables, making them inefficient for weight reduction and ease of use in harsh environments.
Innovation Solution
A flexible printed circuit board (FPCB) harness with conductive tracks is used, connected to other electrical components via an encapsulated connector system that includes elongate terminals and a non-releasable encapsulating body for a robust and reliable connection, which can be integrated into a rigid electrical raft for further weight reduction and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional harnesses are assembled from individual wires and cables, then electrical connections can be established, but the harness becomes bulky, heavy, and difficult to manipulate
Solution Approach 1:
Multiple individual wires and cables are merged into a single integrated flexible printed circuit board, consolidating numerous separate conductors into one unified structure that maintains electrical connectivity while dramatically reducing weight and bulk
Solution Approach 2:
The harness utilizes a flexible printed circuit board with a thin film substrate that provides both mechanical flexibility and electrical conductivity, replacing traditional bulky wire assemblies with a lightweight, deformable structure that can be easily manipulated and installed
2Reliability
If conventional harnesses are assembled from individual wires and cables, then electrical connections can be established, but the harness becomes difficult to manipulate
Solution Approach 1:
The flexible printed circuit board employs a thin, flexible substrate that allows the harness to be easily bent, shaped, and manipulated during installation and maintenance, while the integrated structure ensures reliable electrical connections are maintained throughout the flexible form factor
3Object-affected harmful factors
If an encapsulating body is used to seal the connection formation, then protection against environmental factors is improved, but the connector structure becomes more complex
Solution Approach 1:
The encapsulating body merges multiple protective functions into a single integrated structure that simultaneously provides environmental sealing, mechanical support, and structural stability, eliminating the need for separate protective components and reducing overall connector complexity
Data Source
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AI summary
An electrical harness assembly is provided that comprises a flexible printed circuit electrically connected to one end of an electrical connector. The other end of the electrical connector is presented for connection to another electrical component. Electrical tracks or conductors in the flexible printed circuit terminate in receiving holes. The electrical connector comprises terminals, each of which has a first end that is received in one of the receiving holes to form a connection formation, and a second end which is present for connection to the other electrical device. The connection formation is encapsulated so as to be sealed, thereby providing a reliable and robust connection between the connector and the flexible printed circuit.