Sealed FFC Connector Assembly for Harsh-Environment Termination
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Solution Overview
Problem
The implementation of flat flexible cables in harsh environments and complex applications is hindered by the challenge of developing quick, robust, and low-resistance termination techniques, as well as reliably sealing their connectors against dirt and moisture.
Innovation Solution
A sealed electrical connector design featuring a housing with self-locking conductive terminals and a seal with a slotted opening, combined with a cover that securely fits over the housing, providing a single sealing element around the flat flexible cable and the entire connector assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods are used for FFC connectors, then the connector can be sealed against dirt and moisture, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the seal and cover into a single integrated component that performs both sealing and protective functions. The seal is positioned within the cover and extends to engage with the housing, creating a unified sealing assembly that eliminates the need for separate sealing components and reduces assembly steps.
Solution Approach 2:
The sealing system is divided into distinct functional zones: the seal engages with the housing to provide the primary sealing barrier, while the cover provides additional protection and structural support. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly process.
2Reliability
If complex sealing structures are implemented to seal FFC connectors, then sealing reliability improves, but manufacturing cost and assembly time increase
Solution Approach 1:
The seal is pre-positioned within the cover during manufacturing, so that when the cover assembly is installed on the connector housing, the sealing function is immediately activated without requiring additional assembly steps. This preliminary integration of the seal into the cover structure eliminates time-consuming assembly operations.
Solution Approach 2:
The seal is designed to automatically engage with the housing features when the cover is installed, without requiring additional sealing operations or adjustments. The elastic properties of the seal allow it to self-adjust and seal against the housing, providing a self-service sealing mechanism that reduces assembly complexity and time.
3Reliability
If multiple sealing components are used to ensure reliable sealing, then sealing effectiveness improves, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent merges the seal and cover into a single integrated component that performs both sealing and protective functions. The seal is positioned within the cover and extends to engage with the housing, creating a unified sealing assembly that eliminates the need for separate sealing components and reduces assembly steps.
Data Source
AI summary
A connector comprises a housing defining a receptacle sized to receive a flat flexible cable. A conductive terminal is arranged within the receptacle and adapted to contact an exposed conductor of the flat flexible cable received within the receptacle. A seal is positioned in contact with a front end of the housing and defines a cable receiving slot therethrough aligned with the receptacle. A cover is arranged over the seal and includes a slotted opening aligned with the cable receiving slot of the seal and the receptacle. The cover selectively fixed to the front end of the housing.