Low-Profile Electrical Connector for Flexible Flat Cable
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Solution Overview
Problem
Conventional electrical connectors for flexible flat cables face challenges in providing sufficient clamping force while maintaining a low-profile design, as the displacement of contact arms is restricted by the flat cable, leading to inconsistent contact pressure and potential plastic deformation, which affects reliability and conductivity.
Innovation Solution
The electrical connector features a contact design with a base, a lever, a contact beam, and a pressing arm, where the cam of the actuator presses the contact beam to clamp the flat cable, distributing the force to prevent base lifting and ensure reliable clamping without increasing the connector's size or rigidity, using a tuning fork type contact to maintain a low-profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the lever length is increased to increase clamping force, then the contact pressure on the flat cable is improved, but the connector size increases
Solution Approach 1:
The patent changes the structural parameters of the contact, specifically designing the lever with an optimized length and positioning the cam at a specific distance from the pivot point. This parameter optimization allows achieving sufficient clamping force while maintaining a compact connector size, resolving the contradiction between force and size.
Solution Approach 2:
The patent introduces a cam mechanism that operates in a different dimensional space (rotational motion converting to linear pressing motion). The cam's eccentric design allows the lever to amplify force through rotational leverage, achieving high clamping force without proportionally increasing the linear dimensions of the connector.
2Force
If the lever rigidity is enhanced to increase clamping force, then the contact pressure on the flat cable is improved, but the force required for actuator operation increases
Solution Approach 1:
The patent employs a cam mechanism that provides dynamic force multiplication. The cam's profile is designed to gradually increase the pressing force during rotation, allowing the actuator to operate with moderate force while the lever system amplifies it to generate sufficient clamping force. This dynamic approach avoids the need for excessively rigid levers that would require high operating forces.
3Force
If the contact arm displacement is increased to improve clamping force, then the contact pressure on the flat cable is improved, but the base of the contact lifts from the printed wiring board
Solution Approach 1:
The patent introduces the cam as an intermediary element between the actuator and the lever. The cam's rotational motion mediates the force transmission, converting actuator motion into controlled lever displacement. This intermediary mechanism ensures that the lever arm displaces sufficiently to clamp the cable while the cam's geometry and positioning prevent excessive displacement that would cause base lifting, maintaining contact stability.
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
This design achieves reliable clamping and consistent contact pressure, preventing excessive force and plastic deformation, ensuring durable and efficient electrical connectivity while maintaining a low-profile form factor.
Implementation Method 1
the cam of the actuator presses one end of the contact beam in a direction away from the printed wiring board while pressing the pressing arm and another end of the contact beam in a direction toward to the printed wiring board
Implementation Method 2
distributing the force to prevent base lifting and ensure reliable clamping
Data Source
AI summary
An electrical connector is provided, capable of exerting a sufficient clamping force on a flat cable to reliably provide electrical conductivity while the connector is low-profile. The connector includes a contact having a base, a contact beam, and a pressing arm. The pressing force of a cam of an actuator is transmitted to a base through the pressing arm. Thereby, lift of the base is restrained, and a flat cable is reliably clamped, thereby providing electrical conductivity. Also, elastic deformation of the pressing arm reduces the range of variations in the contact pressure of a contact arm of the contact beam caused by the variations in thickness, gap, dimension, and the like.