Split Cover Electrical Connector for Flat Cable Sealing
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Solution Overview
Problem
Existing electrical connectors for flat flexible cables lack effective sealing and secure attachment solutions, leading to potential electrical failures and reliability issues in densely electronic devices.
Innovation Solution
A split cover electrical connector design featuring a housing with a cover mount, flange, and elastomeric seals that engage with a flat flexible cable, providing a sealed space and secure retention through cover latches and catches, ensuring reliable connection and cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-piece cover design is used, then the structure is simple, but the sealing effectiveness and cable retention are insufficient
Solution Approach 1:
The cover is divided into a first cover and a second cover that are separate components. The first cover includes a first latch and the second cover includes a second latch, allowing independent engagement and sealing actions. This segmentation enables effective sealing through the interaction of seal portions on both covers while maintaining manufacturing simplicity through modular assembly.
2Reliability
If existing connector designs are used, then the connector can be manufactured, but secure cable attachment and retention are not achieved
Solution Approach 1:
The attachment mechanism is segmented into multiple functional elements: a clamp positioned within the cable cavity, first and second latches on separate covers, and corresponding catches on the housing. This segmentation allows each element to perform a specific retention function, achieving secure cable attachment through coordinated action rather than a single complex mechanism.
Solution Approach 2:
The latches and catches are designed as movable elements that engage and disengage dynamically. The first latch on the first cover and second latch on the second cover can move to engage with catches on the housing, providing secure retention while allowing for assembly and disassembly. This dynamic engagement ensures reliable cable retention without requiring permanent or overly complex attachment structures.
3Object-affected harmful factors
If existing connector designs are used, then the connector can be assembled, but effective sealing against environmental factors is not provided
Solution Approach 1:
The sealing system is segmented into a first seal portion on the first cover and a second seal portion on the second cover. These separate seal portions work in conjunction to create an effective sealing barrier, protecting the cable and electrical contacts from environmental factors. The segmentation allows each seal portion to be optimized for its specific location and function while maintaining overall sealing effectiveness.
Solution Approach 2:
The seal portions act as intermediary elements between the covers and the external environment. The first seal portion on the first cover and second seal portion on the second cover create a sealing interface that mediates the protection against environmental factors, allowing the connector to maintain internal protection without requiring the entire housing to be sealed.
Data Source
AI summary
An electrical connector includes a housing with a housing body and a cover mount. The housing has a cable cavity that extends through the cover mount along a connector axis. The electrical connector includes a first cover. The first cover is located on the first side of the connector axis. A second cover is located on a second side of the connector axis. The first cover engages the second cover to retain the covers in their relative positions. The covers also engage the cover mount to retain their position relative to the housing.