Fold-In FFC Seal Structure for Precise Internal Connector Sealing
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Solution Overview
Problem
The challenge of creating reliable and cost-effective seals for flat flexible cables (FFCs) and their connectors, particularly in harsh environments, is exacerbated by the difficulty in forming small sealing features on the internal surfaces of FFCs, which are thin and flexible, leading to tooling complications.
Innovation Solution
A seal design with internal sealing features initially molded externally, featuring a flexible polymer body with distinct seal portions and a foldable second portion that is folded inward to create internal sealing ribs, allowing for optimized feature formation and improved sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional molding methods are used to form internal sealing features on FFC connectors, then the sealing function can be achieved, but the tooling becomes overly complex and manufacturing cost increases
Solution Approach 1:
The patent inverts the traditional molding approach by forming sealing features on the external surface of the mold cavity rather than attempting to form complex internal features directly. The seal is molded with protruding sealing features on its outer surface, which then contact the FFC connector externally to create the seal, eliminating the need for complex internal mold cavities and reducing tooling complexity while maintaining sealing reliability
2Manufacturing precision
If small sealing features are formed on the internal surface of the seal, then effective sealing of thin FFCs is achieved, but the tooling difficulty and manufacturing cost increase significantly
Solution Approach 1:
Instead of forming small sealing features on the internal surface of the seal as traditionally done, the patent forms corresponding sealing features on the external surface of the mold. This external feature formation is much easier to manufacture with standard tooling, and the features are transferred to the seal during molding, achieving the same precise sealing function without the tooling difficulty
Solution Approach 2:
The patent extracts the complex internal feature formation requirement from the mold design by placing all sealing feature formation on the external mold surface. This separates the sealing function from complex internal mold geometry, allowing the use of simpler, more cost-effective molding tools while maintaining the precision needed for sealing thin FFC connectors
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 simplifies the molding process and ensures effective sealing of FFC connectors by enabling precise internal sealing features, enhancing reliability and durability against environmental contaminants.
Implementation Method 1
a seal comprising an elastomeric body defining a generally hollow interior space
Data Source
AI summary
A flat flexible cable (FFC) seal comprises an elastomeric body defining a generally hollow interior space. The body includes a first seal portion surrounding the interior space and comprising an outwardly extending first sealing rib. A cavity is formed into the first seal portion in an axial direction and is sized to receive a portion of a connector component. The body further includes a second seal portion surrounding the interior space and comprising an outwardly extending second sealing rib. The second seal portion extends in the axial direction of the body from an end of the first seal portion. The second seal portion is foldable into the interior space of, and generally under, the first seal portion such that that second sealing rib extends inward into the interior space.