Laterally Offset Contact Element for Flat Ribbon Cables
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Solution Overview
Problem
Existing contact assemblies for flat conductor ribbon cables in steering systems face challenges in ensuring simple and reliable electrical connections between the contact areas and the conductors, often resulting in complex and costly manufacturing processes.
Innovation Solution
The contact element features laterally spaced contact areas within the plane of the strip, allowing for perpendicular contacting of flat conductors through welding or soldering, with insulating materials and guide webs to prevent short circuits and ensure precise alignment, enabling cost-effective and reliable production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If contact areas are arranged vertically one above the other, then the contact element can connect to a single flat conductor ribbon cable, but multiple flat conductor ribbon lines cannot be contacted quickly and easily
Solution Approach 1:
The contact areas are arranged laterally offset from one another in the plane of the strip, transitioning from a vertical stacking arrangement to a lateral distribution arrangement. This dimensional reconfiguration allows multiple flat conductor ribbon lines to be contacted simultaneously in a single plane, significantly improving contacting speed and efficiency without increasing structural complexity
2Reliability
If flat conductors are directly connected to contact points without material removal, then the connection process is simplified, but reliable electrical contact cannot be ensured
Solution Approach 1:
The flat conductors are pre-stripped to remove insulation material at their ends before the contacting process. This preliminary preparation ensures that the exposed conductor surfaces can form reliable electrical connections with the contact areas through welding or soldering, while the stripping operation can be performed in advance during cable manufacturing, not adding complexity to the final assembly process
3Ease of operation
If contact areas are made larger to accommodate multiple conductors, then contacting becomes easier, but the risk of short circuits between adjacent contact areas increases
Solution Approach 1:
The contact element incorporates insulating partitions that divide the contact areas into separate, isolated sections. This segmentation allows each contact area to be sufficiently large for easy contacting while preventing electrical short circuits between adjacent contact areas. The insulating partitions create physical and electrical separation, enabling both ease of operation and safety simultaneously
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 facilitates quick and secure electrical connections for multiple flat conductor ribbon lines, enhancing reliability and preventing short circuits while allowing for efficient production and redundancy in electrical connections.
Implementation Method 1
contact can then be made in a contacting direction perpendicular to the plane of the strip, in particular by welding or soldering
Implementation Method 2
contact can then be made in a contacting direction perpendicular to the plane of the strip, in particular by welding or soldering
Data Source
AI summary
The invention relates to a contact element (16, 17, 116, 117) for contacting at least two flat conductor ribbon cables (8, 108, 208) extending in a ribbon plane and each having at least one flat conductor (21.1), wherein the contact element (16, 17) has at least: two contact areas (18.1, 18.2) insulated from each other and extending in a ribbon plane (50, 60) for receiving and contacting one flat conductor (21.1) of a flat conductor ribbon cable, perpendicular to the ribbon plane (50, 60), and two terminals (20.1, 20.2) for electrical connection to a connecting conductor, wherein the terminals (20.1, 20.2) are each electrically connected to one of the contact areas (18.1, 18.2). Here, the contact areas (18.1, 18.2) are arranged offset from each other in a lateral direction (50) of the ribbon plane (50, 60) so that two flat conductor ribbons can be contacted in one operation.