Spring Clip Connector for Flat Flexible Cable Reliability
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Solution Overview
Problem
Flat flexible cables (FFCs) face challenges in achieving reliable and robust electrical connections, particularly in harsh environments, due to issues like plastic creep and stress relaxation in existing piercing-style crimp terminals, which fail to maintain secure connections over time.
Innovation Solution
A connector system utilizing a spring clip with a resiliently deflectable second beam and a spring latch, which compresses to securely engage the FFC, providing a robust and reliable electrical connection without relying on crimp terminals, using a conductive material like copper or aluminum for the spring clip and a housing with a cover that secures the FFC in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piercing-style crimp terminals are used to establish electrical connection with FFC conductor, then initial electrical connection can be made, but the connection fails to maintain reliability over time due to plastic creep and stress relaxation
Solution Approach 1:
The patent applies the dynamics principle by replacing static crimp terminals with a dynamic spring-based terminal that continuously applies elastic force. The spring terminal can deflect and maintain constant contact pressure on the conductor, compensating for dimensional changes and material relaxation over time, thereby ensuring long-term connection reliability.
Solution Approach 2:
The patent changes the physical state and parameters of the terminal from a rigid crimp structure to an elastic spring structure. This parameter change allows the terminal to transition from a fixed-force application to a variable-force application that adapts to conductor movement and material relaxation, maintaining reliable electrical connection throughout the service life.
2Reliability
If a robust and reliable termination technique is implemented for FFC connectorization, then connection stability improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent segments the terminal into distinct functional components: a spring element for applying contact force, a contact element for electrical connection, and a mounting structure for integration. This segmentation allows each component to be optimized independently while simplifying the overall assembly process and manufacturing.
Solution Approach 2:
The spring terminal is designed to be self-adjusting and self-latching, automatically maintaining contact pressure without requiring external adjustment mechanisms or complex assembly procedures. The elastic nature of the spring provides self-compensation for tolerance variations and installation variations, reducing the need for precise manufacturing and complex termination techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures a stable and reliable electrical connection that is resistant to vibration and maintains contact over time, eliminating the need for crimp terminals and improving the durability of FFC connections in various applications.
Implementation Method 1
The second beam is resiliently deflectable toward the first beam from a relaxed position distal from the first beam to a compressed position proximal to the first beam
Data Source
AI summary
A spring clip has a first beam and a second beam connected to the first beam. The second beam is resiliently deflectable toward the first beam from a relaxed position distal from the first beam to a compressed position proximal to the first beam. The second beam has a spring latch disposed at an end of the second beam and extending toward the first beam. The spring latch engages the first beam to secure the second beam in the compressed position.