Spring Clip FFC Header for Low-Resistance Surface Mounting
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Solution Overview
Problem
Current flat flexible cable (FFC) connectors for surface-mounted applications are complex, costly, and prone to failure due to the need for multiple plastic components and high resistance connections, making them unsuitable for high-volume and complex applications.
Innovation Solution
A self-locking conductive terminal connector with a movable actuator that biases the terminal between an open and clamping position, providing a quick and robust connection by using self-locking spring clips and surface mounting tabs to secure the FFC within a housing, eliminating the need for intermediate connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional FFC harness connectors with multiple plastic housing components are used, then electrical connections can be established, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple traditional connector components (housing, terminal, actuator) into a single integrated connector assembly. The terminal is directly mounted within the housing with the actuator integrated into the same structure, eliminating the need for separate intermediate connectors and reducing the total number of parts while maintaining reliable electrical connections.
Solution Approach 2:
The connector is designed with multi-functionality to serve both as an electrical connection device and a mounting device. The surface mounting tabs extend through the housing to enable direct surface mounting, while the spring clips provide both electrical contact and mechanical retention, reducing the need for separate mounting hardware.
2Reliability
If traditional FFC harness connectors with intermediate connectors are used, then electrical connections can be established, but the manufacturing cost increases
Solution Approach 1:
The patent eliminates intermediate connectors by integrating all necessary functions into a single connector assembly. The terminal is directly mounted within the housing with surface mounting tabs that enable direct surface mounting, reducing the number of components that need to be manufactured, sourced, and assembled, thereby lowering manufacturing costs.
Solution Approach 2:
The connector is designed to be self-contained with all necessary mounting and connection features integrated into the single assembly. The surface mounting tabs provide self-mounting capability, and the spring clips provide self-retention, eliminating the need for additional fasteners or intermediate connection devices.
3Reliability
If traditional FFC connectors with multiple components are used, then electrical connections can be established, but the assembly complexity increases
Solution Approach 1:
The patent combines multiple assembly steps into a single operation by integrating the terminal, housing, and actuator into one pre-assembled unit. This eliminates the need for separate assembly operations for mounting the terminal, attaching the actuator, and securing the FFC, thereby increasing assembly speed and productivity.
Solution Approach 2:
The connector is pre-assembled with the terminal mounted within the housing and the actuator integrated before delivery to the assembly line. The surface mounting tabs are pre-positioned to align with mounting holes, and the spring clips are pre-loaded, allowing for rapid installation in a single operation without requiring complex assembly procedures.
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
This solution enables a reliable, low-resistance connection with reduced manufacturing and assembly complexity, allowing for direct surface mounting of FFCs without intermediate connectors, enhancing the durability and ease of use in high-volume applications.
Implementation Method 1
A self-locking conductive terminal is positioned within the receptacle and includes a first portion arranged in contact with the actuator, and a surface mounting tab extending through the housing and having an end positioned on an exterior surface of the housing. The first portion of the terminal is biased by the actuator between an open position and a clamping position.
Data Source
AI summary
A connector for a flat flexible cable includes a housing defining a receptacle receiving the flat flexible cable, and an actuator movably mounted to the housing. A conductive terminal is positioned within the receptacle and includes a first portion arranged in contact with the actuator, and a surface mounting tab extending through the housing and having an end positioned on an exterior surface of the housing. The first portion of the terminal is biased between an open position and a clamping position by the actuator.