Terminal-less Electrical Connector Assembly for Flat Flexible Conductors
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Solution Overview
Problem
The manufacture of traditional electrical connector assemblies with both an outer housing and an inner electrical terminal is time-consuming and complicated, necessitating a simpler method for securing to electrically conductive structures like flat flexible conductors without separate terminals.
Innovation Solution
An electrical connector assembly design featuring a wire contact wedge with a base and wedge arms, supported by a connector housing and front cover, which allows direct engagement with a flat flexible conductor, eliminating the need for separate electrical terminals by using the conductor's traces and a retaining mechanism for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connector assemblies with outer housing and inner electrical terminal are used, then reliable electrical connection is achieved, but manufacturing time and complexity increase
Solution Approach 1:
The patent combines the outer housing and inner electrical terminal into a single integrated electrical connector assembly. The housing body directly incorporates contact elements and positioning features that traditionally required separate terminals, eliminating the need for additional assembly steps while maintaining reliable electrical connections between conductive structures.
Solution Approach 2:
The housing body is designed to perform multiple functions simultaneously: it provides structural support, houses the electrical contacts, enables mechanical engagement through the wedge mechanism, and ensures electrical connectivity. This multi-functional design eliminates the need for separate terminal components while achieving the same reliability objectives.
2Reliability
If traditional electrical connector assemblies with separate terminals are used, then secure electrical contact is achieved, but assembly complexity increases
Solution Approach 1:
The patent merges the terminal functionality directly into the housing structure. The contact elements are integrated within the housing body rather than being separate components, and the wedge mechanism is built into the housing to provide both mechanical securing and electrical contact simultaneously, reducing overall assembly complexity.
Solution Approach 2:
The electrical contacts and positioning features are nested within the housing body structure. The contact elements are housed within recesses or cavities in the housing, and the wedge mechanism is integrated into the housing geometry, creating a compact nested arrangement that reduces the number of external components needed.
3Productivity
If wire contact wedge with integrating mechanism is used, then manufacturing time is reduced, but structural complexity of individual components increases
Solution Approach 1:
The electrical connector assembly is segmented into distinct functional zones within the housing: the wedge mechanism portion, the contact element portion, and the housing body portion. Each zone is optimized for its specific function, allowing for simplified manufacturing of individual sections while achieving complex overall functionality through their integration.
Solution Approach 2:
The wedge mechanism incorporates dynamic elements that allow the connector to transition between engaged and disengaged states. The wedge arms and positioning features are designed to move and adjust during the connection process, enabling quick assembly and disassembly while maintaining secure electrical contact when engaged.
Data Source
AI summary
An electrical connector assembly includes an electrically conductive structure having a flat flexible conductor that supports a plurality of electrically conductive traces. A wire contact wedge includes a base having an opening extending therethrough and first and second wedge arms that extend from the base. The electrically conductive structure extends through the opening of the base and between the first and second wedge arms. A connector housing supports the wire contact wedge and the electrically conductive structure. The connector housing includes a body having an abutment surface that engages a corresponding abutment surface of the base of the wire contact wedge. A front cover is supported on the connector housing and includes a retaining arm that cooperates with a corresponding protrusion provided on the wire contact wedge.