Flat Cable Connector Assembly With Stuffer-Locked Contact Alignment
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Solution Overview
Problem
The electrical connection between a conductive element and a flat cable is unreliable and difficult to automate due to alignment issues, such as lateral or longitudinal offsets, which reduce the contact area and efficiency of electrical conduction.
Innovation Solution
A connector assembly with a connector housing, terminal, and stuffer that ensures proper alignment and intimate contact between the conductive elements, using features like alignment wings, internal divider walls, and a stuffer that urges the terminal toward the flat cable to create a secure mechanical connection, which can be welded for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal is connected to a flat cable using an intermediate connection component, then electrical connection is achieved, but the connection becomes unreliable and difficult to automate due to alignment issues
Solution Approach 1:
The connector is divided into separate components: a housing, a terminal with conductive members, and a stuffer. This segmentation allows each component to be manufactured and assembled independently, enabling automated assembly while maintaining reliable electrical connections through precise alignment features built into each segment.
Solution Approach 2:
The stuffer acts as an intermediary component that facilitates proper alignment between the terminal and flat cable. The stuffer engages with alignment wings on the housing and pushes the conductive members into intimate contact with the flat cable contacts, mediating the alignment process to ensure reliable electrical connection while enabling automated assembly.
2Reliability
If alignment features are added to ensure proper positioning, then electrical connection reliability improves, but device complexity increases
Solution Approach 1:
Multiple alignment functions are merged into the stuffer component. The stuffer combines the alignment wing engagement feature, the pushing mechanism for intimate contact, and the positioning function all in one element. This merging reduces overall device complexity compared to having separate alignment features distributed across multiple components.
Solution Approach 2:
The stuffer serves multiple functions simultaneously: it engages with alignment wings for positioning, pushes the conductive members into contact with the flat cable, and maintains mechanical pressure for reliable electrical connection. This multi-functionality reduces the need for separate alignment mechanisms, thereby reducing device complexity while improving reliability.
Data Source
Figure 1~3
Figure 2
Figure 4A~4B
AI summary
A connector assembly includes a connector housing. The connector housing includes a first side having a first opening. The first opening includes a first planar surface within the connector housing. The connector housing includes a second side having a second opening. The connector assembly includes a terminal with an attachment portion and a conductive member. The conductive member includes a tanged portion. The attachment portion includes a socket opening accessible through the second opening of the connector housing. The connector assembly includes a stuffer insertable into the first opening of the connector housing. The tanged portion of the terminal is engageable with the stuffer to urge the conductive member toward the first planar surface.