Spring Clip Connector for Flat Flexible Cable
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Solution Overview
Problem
Flat flexible cables (FFCs) face challenges in achieving reliable and robust electrical connections, especially in harsh environments, due to issues like plastic creep and stress relaxation in existing piercing-style crimp terminals.
Innovation Solution
A connector assembly featuring a spring clip with a first beam and a second beam that is resiliently deflectable, secured by a spring latch, providing a robust and reliable electrical connection by compressing the FFC's insulation and contacting the conductor, thereby maintaining a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piercing-style crimp terminals are used to establish electrical connection with FFC conductor, then the connection can be initially established, but the connection reliability deteriorates over time due to plastic creep and stress relaxation in harsh environments
Solution Approach 1:
The patent employs a dynamic spring mechanism that continuously applies force to maintain electrical connection. The spring element is configured to deflect and apply contact force to the conductor, ensuring consistent pressure compensates for any relaxation or creep over time, thereby maintaining connection reliability throughout the operational duration.
Solution Approach 2:
The invention changes the physical state of the terminal from a static crimp structure to a dynamic spring-loaded structure. This parameter change allows the terminal to adapt its contact force over time, maintaining optimal electrical connection pressure despite environmental factors like temperature cycling and vibration that cause plastic creep and stress relaxation.
2Reliability
If a spring mechanism is used to maintain continuous contact force, then connection reliability is improved, but the device complexity increases compared to simple crimp terminals
Solution Approach 1:
The patent merges the spring mechanism with the terminal body into an integrated structure. The spring element is formed as part of the terminal component itself, combining the electrical contact function with the force application mechanism, thereby reducing overall device complexity while maintaining reliable continuous contact.
Solution Approach 2:
The spring mechanism is designed to be self-regulating, automatically adjusting its contact force based on the position and movement of the FFC conductor. The terminal requires no external actuation or control systems, as the spring naturally maintains the necessary contact pressure through its elastic properties, simplifying the overall system.
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 robust and reliable electrical connection that is resistant to vibration and movement, maintaining contact over time without the degradation seen in traditional crimp terminals.
Implementation Method 1
a second beam (230) connected to the first beam (210) and resiliently deflectable toward the first beam (210) from a relaxed position distal from the first beam (210) to a compressed position proximal to the first beam (210)
Data Source
AI summary
A spring clip includes a first beam and a second beam connected to the first beam and 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 extending toward the first beam. The spring latch engages the first beam to secure the second beam in the compressed position. The clip may be positioned in a housing having a rotatable cover formed to compress the clip against a conductor when moved to a closed position.