Multi-Wire Planar Cable Terminal Assembly for Battery Modules
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Solution Overview
Problem
Conventional battery connector systems using flexible flat cables face challenges in reliable electrical connections and high voltage creepage distance requirements, particularly in the automotive industry, due to the difficulty in terminating flat wires and maintaining separation distances.
Innovation Solution
A terminal assembly utilizing a multi-wire planar cable with a common jacket and longitudinal grooves allows for controlled separation of flat wires, enabling reliable crimping into terminals and increased creepage distance by using F-crimp connections and a specific housing design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flexible flat cables are used to reduce wire thickness, then the cable thickness is reduced and assembly is simplified, but termination becomes difficult and electrical connection reliability decreases
Solution Approach 1:
The flat cable is segmented into individual conductors that can be separated from each other. The housing includes separate cavities for each conductor, allowing independent termination while maintaining the flexibility and thin profile of the original flat cable structure.
Solution Approach 2:
The housing acts as an intermediary component that receives the flat cable, separates its conductors, and provides individual cavities for terminal attachment. This mediator enables reliable termination without requiring modification to the flat cable itself.
2Ease of manufacture
If pierce crimp terminals are used to connect to flat wires, then assembly is simplified, but electrical connection reliability is reduced and loading into common housing is difficult
Solution Approach 1:
The terminal assembly is segmented into individual terminals, each housed in its own cavity. This allows each terminal to be optimally designed for reliable electrical connection (using conventional crimping) while maintaining ease of assembly through the modular housing structure.
3Length of stationary object
If flat wires are separated to increase creepage distance, then high voltage requirements are met, but cutting or tearing the flexible flat cable exposes conductors leading to short circuits
Solution Approach 1:
The housing is designed with pre-formed cavities and conductor guides that direct each flat cable conductor into its designated cavity before termination. This preliminary arrangement ensures proper separation and insulation without requiring cutting or tearing of the cable, thus maintaining creepage distance while preventing conductor exposure.
Solution Approach 2:
The housing serves as an intermediary structure that provides physical separation and insulation between conductors. The cavity walls act as insulating barriers that maintain required creepage distances while safely containing the conductors during the termination process.
Data Source
Figure 1~3
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AI summary
A terminal assembly includes a multi-wire planar cable (118) having a plurality of flat wires (140) and a common jacket (160) for the plurality of flat wires. The jacket has grooves (168) between adjacent flat wires for controlled separation of the flat wires and surrounding jacket portions at an end (158) of the multi-wire planar cable into separated jacketed wire portions (166) extending a length (182) of the flat wires each including an insulating sleeve (180) and a terminating end (184) of the flat wire. The terminating ends of the flat wires are exposed beyond the insulating sleeves. Terminals are attached to the terminating ends of corresponding flat wires.