Patent Application
20200313326
The invention generally relates to an electrical cable assembly, particularly to a flat electrical cable assembly.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
According to one embodiment of the invention, an electrical cable assembly is provided. The electrical cable assembly includes a multiconductor flat cable having a first electrically conductive wire and a second electrically conductive wire arranged in a coplanar fashion with each other. The first and second wires are encased within a planar dielectric structure. A slot is defined in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire. Exposed portions of the first and second wires extend beyond the first and second wing features.
An example embodiment having one or more features of the electrical cable assembly of the previous paragraph includes a connector having a housing formed of a dielectric material, a first electrical terminal and a second electrical both disposed within the housing. The exposed first wire is attached to the first terminal the exposed second wire is attached to the second terminal.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the first and second terminals define prongs that are received within holes defined in portions of the first and second wing features, thereby retaining the first and seconds wires to the first and second terminals.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the prongs are a pair of triangular prongs. The pair of triangular prongs may be a pair of right triangular prongs. A first prong in the pair of right triangular prongs may be arranged in reverse of a second prong in the pair of right triangular prongs.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the second wire is shorter than the first wire. The first wire is bent such that it crosses over the second wire. In this embodiment, the first terminal is laterally offset from the first wire within the connector.
An example embodiment having one or more features of the electrical cable assembly of the previous paragraph includes a cover formed of dielectric material attached to the housing, thereby enclosing the first and second terminals.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the first and second terminals each define a groove configured to receive the first and second wires and are sized to provide a friction fit between the first and second terminals and the first and second wires.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the first and second wires are attached to the first and second terminals using a welding process.
An example embodiment having one or more features of the electrical cable assembly of the previous paragraph includes a connector comprising a housing formed of a dielectric material and an electrical terminal disposed within the housing. The first wire is bent such that the exposed first wire is aligned with the second exposed wire. The exposed second wire is attached to the electrical terminal. The exposed first wire is attached to the exposed second wire, thereby attaching the exposed first wire to the electrical terminal. In this embodiment of the electrical cable assembly, the electrical terminal may define prongs. A portion of the second wing features may be attached to the electrical terminal by inserting the prongs within holes defines in portions of the second wing features, thereby retaining the second wire to the electrical terminal. The portion of the first wing features may also be attached to the electrical terminal by inserting the prongs within the holes defined in portions of the first wing features, thereby retaining the first wire to the electrical terminal.
In an example embodiment having one or more features of the electrical cable assembly of the previous paragraph, the first and second wires have a substantially round cross section and wherein the first wire has a different cross sectional area than the second wire.
According to another embodiment of the invention, a method of forming an electrical cable assembly is provided. The method includes the steps of providing a multiconductor flat cable comprising a first and second electrically conductive wire arranged in a coplanar fashion with each other and encased within a planar dielectric structure, cutting a slot in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire, and removing portions of the dielectric structure from ends of the first and second wires, thereby exposing portions of the first and second wires, wherein portions of the first and second wing features remain.
An example embodiment having one or more features of the method of the previous paragraph includes the steps of providing a connector comprising a housing formed of a dielectric material, inserting first and second electrical terminals within the housing, and attaching the exposed first wire to the first terminal and attaching the exposed second wire to the second terminal.
In an example embodiment having one or more features of the method of the previous paragraph, the first and second terminals define prongs and the method further includes the step of attaching the portions of the first and second wing features to the first and second terminals by inserting the prongs within holes defined in the portions of the first and second wing features, thereby retaining the first and seconds wires to the first and second terminals.
In an example embodiment having one or more features of the method of the previous paragraph, the holes in the portions of the first and second wing features are formed by puncturing the portions of the first and second wing features using the prongs.
An example embodiment having one or more features of the method of the previous paragraph includes the steps of cutting the second wire such that it is are shorter than the first wire and bending an end potion of the first wire such that it crosses over the second wire. In this embodiment, the first terminal is laterally offset from the first wire within the connector.
An example embodiment having one or more features of the method of the previous paragraph includes the steps of providing a cover formed of dielectric material configured to attach to the housing and attaching the cover to the housing, thereby enclosing the first and second terminals.
In an example embodiment having one or more features of the method of the previous paragraph, the first and second terminals each define a groove configured to receive the first and second wires and sized to provide a friction fit between the first and second terminals and the first and second wires.
In an example embodiment having one or more features of the method of the previous paragraph, the first and second wires are attached to the first and second terminals using a welding process.
In an example embodiment having one or more features of the method of the previous paragraph, the step of inserting first and second electrical terminals within the housing is performed prior to the steps of attaching the exposed first wire to the first terminal and attaching the exposed second wire to the second terminal.
An example embodiment having one or more features of the method of the previous paragraph includes the steps of providing a connector comprising a housing formed of a dielectric material, inserting an electrical terminal within the housing, attaching the exposed second wire to the first terminal, cutting the second wire such that it is shorter than the first wire, bending the first wire such that the exposed first wire is aligned with the second exposed wire, and attaching the exposed first wire to the exposed second wire, thereby attaching the exposed first wire to the electrical terminal. According to this embodiment, the electrical terminal may define prongs and the method may further include the steps of attaching a portion of the second wing features to the electrical terminal by inserting the prongs within holes defines in the portions of the second wing features, thereby retaining the second wire to the electrical terminal and attaching the portion of the first wing features to the electrical terminal by inserting the prongs within the holes defined in the portions of the first wing features, thereby retaining the first wire to the electrical terminal.
According to yet another embodiment of the invention, an apparatus configured to manufacture an electrical cable assembly is provided. The apparatus includes a transport mechanism configured to move a multiconductor flat cable, from a spool and through the apparatus. The flat cable includes first and second electrically conductive wires arranged in a coplanar fashion with each other and encased within a planar dielectric structure. Th apparatus also includes a cutting mechanism configured to cut a slot in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire and a stripping mechanism configured to remove portions of the dielectric structure from ends of the first and second wires, thereby exposing portions of the first and second wires. The stripping mechanism is further configured to retain portions of the first and second wing features.
In an example embodiment having one or more features of the apparatus of the previous paragraph, the cutting mechanism is also configured to cut the second wire such that it is shorter than the first wire. The apparatus further comprises a bending mechanism that is configured to bend the third wire such that the exposed first wire is aligned with the second exposed wire or bend the first wire such that it crosses over the second wire.
In yet one more embodiment of the invention, an electrical terminal is provided. The electrical terminal includes a connection portion configured to interconnect with a corresponding mating terminal, a wire attachment portion configured to receive a wire cable, and an insulation attachment portion defining a pair of triangular prongs arranged so as to receive the wire cable between the pair of triangular prongs, wherein the pair of triangular prongs are configured to puncture through a dielectric structure surrounding the wire cable and create holes in the dielectric structure in which the pair of triangular prongs are received.
In an example embodiment having one or more features of the electrical terminal of the previous paragraph, the electrical terminal defines a groove in which the wire cable is received, The groove is sized to provide a friction fit between the electrical terminal and the wire cable.
In an example embodiment having one or more features of the electrical terminal of the previous paragraph, the pair of triangular prongs is a pair of right triangular prongs. A first prong in the pair of triangular prongs is arranged in reverse of a second prong in the pair of right triangular prongs.
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
As used herein reference numbers without letter suffixes may generically refer to a feature while reference numbers with suffixes may refer to specific features.
As illustrated in
As illustrated in
The terminals 30 have a connecting portion 34 configured to interconnect with a corresponding mating terminal (not shown) and an attachment portion 36 configured to attach the terminal 30 to a wire 14. The connecting portion 34 of the illustrated example terminal 30 is a female connecting portion 34 configured to receive a male connecting portion of the mating terminal. Other embodiments may be envisioned in which the connection portion is a male connection portion. In other alternative embodiments, the housing may include terminals having a mixture of different connection types.
The exposed wire portions 22 are attached to the attachment portions 36 of the terminals 30 by two different means. As shown in
As seen in
Returning now to
As illustrated in
STEP 202, PROVIDE A MULTICONDUCTOR FLAT CABLE COMPRISING A FIRST AND SECOND ELECTRICALLY CONDUCTIVE WIRE ARRANGED IN A COPLANAR FASHION WITH EACH OTHER AND ENCASED WITHIN A PLANAR DIELECTRIC STRUCTURE, includes providing a multiconductor flat cable 12 comprising a electrically conductive wire 14, 14a, 14b arranged in a coplanar fashion with each other and encased within a planar insulative structure 16;
STEP 204, CUT A SLOT IN THE PLANAR DIELECTRIC STRUCTURE INTERMEDIATE THE FIRST AND SECOND WIRES, includes cutting a slot in the planar insulative structure 16 intermediate the wires 14, 14a, 14b, thereby forming 20, 20a, 20b in the planar insulative structure 16 extending from the wires 14, 14a, 14b;
STEP 206, REMOVE PORTIONS OF THE DIELECTRIC STRUCTURE FROM ENDS OF THE FIRST AND SECOND WIRES, includes removing portions of the dielectric structure from ends of the wires 14, 14b, 14b, thereby creating exposed wire portions 22, 22a, 22b, wherein portions of the insulation wings 20, 20a, 20b remain;
STEP 208, PROVIDE A CONNECTOR COMPRISING A HOUSING FORMED OF A DIELECTRIC MATERIAL, includes providing a connector 24 comprising a housing 26 formed of a dielectric material;
STEP 210, INSERT FIRST AND SECOND ELECTRICAL TERMINALS WITHIN THE HOUSING, includes inserting terminals 30a, 30b within channels 28 formed in the housing 26;
STEP 212, CUT THE SECOND WIRE SUCH THAT IT IS ARE SHORTER THAN THE FIRST WIRE, is an optional step that includes cutting the one wire 14 such that it is are shorter than another wire 14a, 14b;
STEP 214, BEND AN END POTION OF THE FIRST WIRE SUCH THAT IT CROSSES OVER THE SECOND WIRE, is an optional step that includes bending an end potion of the wire 14b such that it crosses over the wire 14;
STEP 216, ATTACH THE EXPOSED FIRST WIRE TO THE FIRST TERMINAL AND ATTACH THE EXPOSED SECOND WIRE TO THE SECOND TERMINAL, is an optional step that includes attaching the exposed wire portion 22b to one terminal 30a and attaching the other exposed wire portion 22 to another terminal 30b. The terminals 30a, 30b may each define a groove 38 that is configured to receive the exposed wire portions 22, 22b and sized to provide a friction fit between the terminals 30a, 30b and the exposed wire portions 22, 22b. The exposed wire portions 22, 22b may be further attached to the terminals 30a, 30b using a welding process. The terminal 30a is laterally offset from the wire 14b within the housing 26. STEP 210 is preferably performed prior to STEP 216;
STEP 218, ATTACH THE PORTIONS OF THE FIRST AND SECOND WING FEATURES TO THE FIRST AND SECOND TERMINALS BY INSERTING THE PRONGS WITHIN HOLES DEFINED IN THE PORTIONS OF THE FIRST AND SECOND WING FEATURES, is an optional step wherein the terminals 30a, 30b define prongs 42 and includes attaching the insulation wings 20, 20b to the terminals 30a, 30b by inserting the prongs 42 within holes 44 defined in the insulation wings 22, 22b, thereby retaining the wires 14, 14b to the terminals 30a, 30b. The holes 44 in the insulation wings 20, 20b may be formed by puncturing the insulation wings 20, 20b using the prongs 42;
STEP 220, BEND THE FIRST WIRE SUCH THAT THE EXPOSED FIRST WIRE IS ALIGNED WITH THE SECOND EXPOSED WIRE, is an optional step that includes bending a wire 14a such that the exposed wire portion 22a is aligned with the exposed wire portion 22;
STEP 222, ATTACH THE EXPOSED FIRST WIRE TO THE EXPOSED SECOND WIRE, is an optional step that includes attaching the exposed wire portion 22b to the exposed wire portion 22, thereby attaching the exposed wire portion 22b to the terminal 30b;
STEP 224, ATTACH A PORTION OF THE SECOND WING FEATURES TO THE ELECTRICAL TERMINAL BY INSERTING THE PRONGS WITHIN HOLES DEFINED IN THE PORTIONS OF THE SECOND WING FEATURES, is an optional step that includes attaching a portion of the insulation wings 20 to the terminal 30b by inserting the prongs 42 within holes 44 defined in the insulation wings 20, thereby retaining the wire 14 to the terminal 30b;
STEP 226, ATTACH THE PORTION OF THE FIRST WING FEATURES TO THE ELECTRICAL TERMINAL BY INSERTING THE PRONGS WITHIN THE HOLES DEFINED IN THE PORTIONS OF THE FIRST WING FEATURES, is an optional step that includes attaching the insulation wings 20a to the terminal 30b by inserting the prongs 42 within the holes 44 defined in the insulation wings 20a, thereby retaining the wire 14a to the terminal 30b;
STEP 228, PROVIDE A COVER CONFIGURED TO ATTACH TO THE HOUSING, includes providing a cover 50 formed of dielectric material configured to attach to the housing 26; and
STEP 230, ATTACH THE COVER TO THE HOUSING, includes attaching the cover 50 to the housing 26, thereby enclosing the terminals 30a, 30b.
Accordingly, an electrical cable assembly 10 is presented. The electrical cable assembly 10 provides the benefits of easier packaging of the cable assembly due to the reduced thickness of the electrical cable assembly 10 compared to conventional automotive wiring assemblies. It also provides the benefit of ease of automated assembly due to the insertion of the terminals 30 within the housing 26 which allows all of the wires 14 to be connected the terminals 30 simultaneously by pressing the exposed wire portions 22 into the grooves 38 of the terminals 30. The terminal/wire interfaces are also more easily accessible by a welding device. This assembly also eliminates the needs for locking features in the housing 26 to retain the terminals 30 within the housing 26 and the problems created when these locking features are not properly engaged with the terminal 30. The electrical cable assembly 10 also avoids problems experienced during conventional insertion of a terminal attached to a small gauge wire into a connector housing caused by a low column strength of small gauge wires. An apparatus 100 for forming the electrical cable assembly 10, a method 200 of forming the electrical cable assembly 10, and an electrical terminal 30 configured for use in the electrical cable assembly 10 is also presented.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context. Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.
