Stapled Electrical Contact for FFC Cables
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Solution Overview
Problem
Existing flex cable electrical connectors are limited in their ability to connect conductors thicker than 0.006 inches, requiring removal of insulation and use of individual crimped connectors, which is inefficient and costly.
Innovation Solution
A flexible flat connector cable with a staple feature having two outwardly extending lances with knife edges that pierce through the conductor and deform back to form a stapled connection, allowing attachment without removing insulation and supporting conductors up to 0.008 inches thick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor piercing type connection is used, then electrical contact and precise locationing are improved, but the solution becomes limited to conductors thinner than 0.006 inch
Solution Approach 1:
The patent changes the geometric parameters of the connection structure by transitioning from a traditional piercing contact to a staple feature with two lances. The lances are designed with specific dimensions (length, width, curvature radius) that enable them to pierce and deform around thicker conductors (0.008 inch and greater) while maintaining reliable electrical contact. This parameter modification allows the same piercing principle to work across a broader range of conductor thicknesses.
Solution Approach 2:
The connection structure is segmented into distinct functional components: the staple feature with two separate lances, each lance having a pointed tip for piercing and a curved body for deformation. This segmentation allows each component to perform its specific function optimally - the tips penetrate the conductor insulation and conductor, while the curved bodies deform around the conductor to create mechanical and electrical connection.
2Adaptability or versatility
If insulation is removed and individual conductor connectors are crimped, then connection of thicker conductors is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple functions into a single integrated electrical contact component. The staple feature with two lances simultaneously performs insulation piercing, conductor piercing, and mechanical retention functions that would otherwise require separate operations and components. This single component can connect to the entire cable assembly (insulation plus conductor) without requiring insulation removal or separate crimping operations for individual conductors.
Solution Approach 2:
The electrical contact design achieves multi-functionality by enabling a single component to connect to conductors of various thicknesses (including 0.008 inch and greater) without requiring different connection methods or additional processing steps. The staple feature universally handles both the insulation layer and the conductor, making the connection process adaptable to different cable specifications while maintaining a consistent manufacturing procedure.
3Productivity
If conventional piercing connection is used for thicker conductors, then connection speed is maintained, but reliable electrical contact cannot be achieved
Solution Approach 1:
The connection process incorporates dynamic deformation of the lance structures. During installation, the lances are inserted in a straight configuration, then deformed into a curved shape that wraps around the conductor. This dynamic transformation allows the connection to adapt to the conductor's position and dimensions, ensuring reliable electrical contact while maintaining a simple, fast insertion process that requires no complex adjustment steps.
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
Enables efficient and cost-effective piercing-type connections for thicker conductors without insulation removal, improving electrical contact and reducing connection time and energy costs.
Implementation Method 1
The lances are adapted to be deformed back towards the electrical conductor to form a stapled connection
Data Source
AI summary
A flexible flat connector cable electrical contact including a first connection section adapted to be connected to an electrical conductor of a flexible flat conductor (FFC) cable; and a second connection section electrical coupled to the first connection section and adapted to be electrically connected to another member. The first connection section includes at least one staple feature having a hole and only two outwardly extending lances at the hole. Each lance has a pointed tip adapted to pierce through the electrical conductor of the FFC cable. The lances are adapted to be deformed back towards the electrical conductor to form a stapled connection of the first connection section to the FFC cable with only the two lances at the staple feature.