Polarized Flat Cable Connector With Locking Retention
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Solution Overview
Problem
Existing electrical connectors for flat flexible cables lack effective mechanisms to securely retain the cables in place, leading to potential disconnection and unreliable electrical connections.
Innovation Solution
The electrical connector features a housing with a terminal cavity designed to accommodate flat cables, including a polarizer to prevent incorrect insertion, a cable lock with a lock tongue to secure the cable, and a terminal lock to retain the electrical terminal in position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electrical connector design is used for flat flexible cables, then the cable management is difficult and connections are unreliable, but adding retention mechanisms increases device complexity
Solution Approach 1:
The connector is divided into distinct functional components: a housing defining a terminal cavity, a polarizer element, a cable lock with lock tongue, and a terminal lock. Each segment performs a specific function (guidance, orientation prevention, cable retention, terminal retention) allowing the complex retention system to be modular and manageable despite its multiple parts.
Solution Approach 2:
The polarizer is positioned in advance within the terminal cavity to prevent incorrect cable insertion before the cable is even connected. The housing structure is pre-configured with the terminal cavity and polarizer arrangement, so that proper cable orientation is enforced before the cable lock engages to secure the connection.
2Reliability
If retention mechanisms are added to secure the cable, then cable disconnection is prevented, but the ease of operation for cable insertion and removal is reduced
Solution Approach 1:
The cable lock and terminal lock are designed as movable components that can transition between engaged and disengaged states. The lock tongue can move to engage or disengage from the cable, and the terminal lock can move to secure or release the electrical terminal, allowing the connector to be secure during use but easily operated when needed.
3Adaptability or versatility
If the terminal cavity width is made greater than height to accommodate flat cables, then cable accommodation is improved, but the precision of cable positioning is reduced
Solution Approach 1:
The terminal cavity is designed with asymmetric dimensions where the width is greater than the height, matching the asymmetric geometry of flat flexible cables. This asymmetric configuration provides adequate accommodation space for the cable while the polarizer element introduces a directional reference that restores positioning precision by preventing rotation or misalignment of the cable within the cavity.
Solution Approach 2:
The polarizer acts as an intermediary element between the terminal cavity and the flat flexible cable. It mediates the interaction by providing a physical reference that guides cable positioning and prevents incorrect orientation, thereby maintaining positioning precision despite the generous cavity dimensions needed for cable accommodation.
Data Source
AI summary
An electrical connector includes a housing. The housing defines a terminal cavity that extends along a connector axis. The terminal cavity has a height that is perpendicular to the connector axis. The terminal cavity has a width that is perpendicular to the connector axis and also perpendicular to the height. The width is greater than the height. The terminal cavity adapted to accommodate a flat cable inserted in an insertion direction parallel to the connector axis. The electrical connector also includes a polarizer that extends parallel to the height. The polarizer is located within the width. The polarizer is adapted to prevent insertion into at least part of the terminal cavity.