Sealed In-Line Connector Assembly for Flat Flexible Conductors

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Solution Overview

Problem

Existing electrical connector assemblies fail to provide quick and easy mechanical and electrical connections between flat flexible conductors while effectively resisting the entry of contaminants in a sealed environment.

Innovation Solution

An electrical connector assembly comprising a conductive structure, a wire contact wedge, a connector housing, and a front cover, which includes a matte seal assembly and a radial seal to create a sealed environment that prevents contaminant ingress, while ensuring secure electrical connections between flat flexible conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional electrical connector assemblies are used, then mechanical and electrical connections can be established, but the connection process is time-consuming and complex

Engineering Contradiction:

Improveconnection speedVSAvoidconnector assembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The connector assembly is divided into distinct modular components: a first connector housing with a first flat flexible conductor, a second connector housing with a second flat flexible conductor, and interlocking engagement features. This segmentation allows for simplified assembly where each module can be independently prepared and connected, reducing overall connection time and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flat flexible conductors are pre-positioned within their respective connector housings with contacts already aligned and ready for engagement. The housings include pre-formed sealing structures and alignment features that are prepared in advance, eliminating the need for complex assembly operations during the connection process and enabling quick plug-and-play connectivity.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional electrical connector assemblies are used, then electrical connections can be established, but contaminants can enter the connector housing

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcontaminant ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A flexible sealing member, resembling a lip seal, is positioned at the interface between the two connector housings. This flexible film-like structure conformally seals around the flat flexible conductors as they pass through, creating an effective barrier against contaminant ingress while maintaining electrical connectivity. The flexibility allows it to adapt to the conductor shapes and movement.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing structure is nested within the connector housing design, with the flexible sealing member integrated into the housing walls and positioned to seal around the conductors. The seal creates a nested sealed environment that protects the internal electrical contacts from contaminants while allowing the conductors to pass through the sealing barrier.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If sealed environments are created to prevent contaminant ingress, then reliability improves, but manufacturing complexity increases

Engineering Contradiction:

Improvesealed connection reliabilityVSAvoidsealed connector manufacturability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The flexible sealing member is designed as a simple lip-shaped component that can be molded as a single piece or easily attached to the connector housings. This flexible film structure provides effective sealing without requiring complex multi-component assemblies, maintaining ease of manufacture while achieving reliable contamination protection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing function is merged into the connector housing structure itself, with the flexible sealing member integrated as part of the housing assembly. This combination eliminates the need for separate complex sealing systems and allows the sealing feature to be manufactured together with or as part of the connector housings, simplifying the overall manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12537331B2Electrical connector assembly for a terminal-less sealed in-line connection system

Publication Date: 2026.01.27 LEAR CORP

AI summary

An electrical connector assembly quickly and easily provides mechanical and electrical connections between two flat flexible conductors, each having multiple electrically conductive traces provided thereon, in a sealed environment that resists the entry of contaminants therein. The electrical connector assembly includes an electrically conductive structure, a wire contact wedge supporting the electrically conductive structure, a connector housing supporting the wire contact wedge and the electrically conductive structure, and a front cover supported on the connector housing.