Front-Load FFC Connector Assembly for Vibration-Resistant Termination
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Solution Overview
Problem
There is a need for quick, robust, and low resistance termination techniques for narrow-pitch flat flexible cables (FFCs) to enable reliable mating with components like printed circuit boards (PCBs), while withstanding vibration and thermal cycling in harsh environments.
Innovation Solution
A connector assembly comprising a header and plug with conductive contacts and terminals, allowing for secure electrical connections through a front-loading mechanism, using a cable stiffening element to support the FFC and ensure alignment and secure engagement with the header contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional round wire architectures are used, then mechanical strength and ease of termination are improved, but profile height and weight increase
Solution Approach 1:
The patent employs flat flexible cables with thin film conductors embedded in flexible insulation, replacing traditional round wire architectures. This enables significantly reduced profile height while maintaining electrical connectivity and flexibility for complex routing applications
2Ease of operation
If FFCs are used to reduce profile and weight, then ease of routing and flexibility are improved, but termination reliability and mechanical robustness worsen
Solution Approach 1:
The connector is divided into separate plug and header components with distinct termination zones. The plug contains terminals that receive FFC conductors through welding, while the header provides receptacle engagement. This segmentation allows optimized termination techniques for each component, improving overall reliability
Solution Approach 2:
The FFC conductors are pre-terminated to the plug terminals using welding or other robust techniques before final assembly. This preliminary termination ensures reliable electrical connections are established prior to connector engagement, addressing the fragility issue of FFCs
3Productivity
If narrow-pitch FFCs are used to increase circuit density, then electrical connectivity is improved, but vulnerability to vibration and mechanical stress increases
Solution Approach 1:
The connector design nests the FFC conductors within protective housing structures and positions them within recesses or channels of the plug and header. This nesting provides mechanical protection against vibration and stress while maintaining the narrow-pitch configuration for high circuit density
4Strength
If robust termination techniques are developed to strengthen FFC connections, then mechanical strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces mechanical termination methods (such as crimping or screw terminals) with welding or other non-mechanical joining techniques for the FFC conductor-to-terminal connections. This substitution provides stronger, more reliable connections while potentially simplifying the manufacturing process through automated welding operations
Data Source
AI summary
A connector assembly for a flat flexible cable (FFC) comprises a header and a plug receivable within the header. The header includes conductive contacts arranged therein. The plug includes conductive terminals and defines first openings and second openings. The first openings are defined on a first side of the plug and expose a weld pad of each of the terminals for electrically connecting each terminal to an exposed conductor of an FFC. The second openings are defined on a second side of the plug and expose a contact area of each of the terminals for electrically engaging with a respective one of the contacts of the header. The plug is insertable into the header between an initial position wherein the contacts are not in contact with the terminals, and a final position wherein the contacts are engaged with the terminals.