Patent Application
20240079803
The present disclosure relates generally to devices and methods for securing a flat cable to a conductive element. In general, electrically connecting a conductive element (i.e., a wire, cable, or other electrical conductor) to a flat cable may include an intermediate connection component such as a terminal. The electrical connection of a flat cable to a terminal may be unreliable and difficult to automate.
In some embodiments 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.
In some embodiments, a connector housing includes a first side having a first opening. A second side includes a plurality of second openings. A cavity extends between the first opening and the plurality of second openings. The cavity includes a first planar surface. A deflectable biasing member is located opposite from the first planar surface and biased to deflect toward the first planar surface. A plurality of apertures extends through the first planar surface of the connector housing.
In some embodiments, a method of securing a flat cable to a terminal includes providing a connector housing. The connector housing includes a first side having a first opening and a second side with a second opening. A connector housing body includes a cavity extending between the first opening and the second opening. An aperture extends through a bottom surface of the connector housing body. A welding element is provided. The terminal is inserted into the connector housing. The terminal includes a second conductive contact region. The flat cable is inserted into the connector housing. The flat cable includes a first conductive contact region. Mechanical contact is created between the first conductive contact region and the second conductive contact region. The first conductive contact region of the flat cable is welded to the second conductive contact region of the terminal through the aperture of the connector housing.
This written disclosure describes illustrative embodiments that are non-limiting and non-exhaustive. In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
Reference is made to illustrative embodiments that are depicted in the figures, in which:
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.
According to some embodiments of this disclosure, an electrical connector assembly is provided, the electrical connector assembly including a connector housing, a terminal, a flat cable, and a stuffer. The electrical connector assembly is configured to electrically connect a conductive element (i.e., a wire, cable, or other electrical conductor) to the flat cable. The conductive element is electrically connected to the terminal, and the terminal is electrically connected to the flat cable, such that an electrical signal may travel from the conductive element, through the terminal, and to the flat cable (or vice-versa).
The electrical connection between the terminal and the flat cable may introduce problems in manufacturing the electrical connector assembly and may affect the durability of the electrical connector assembly. For instance, it may be difficult to reliably align the terminal with the conductive element of the flat cable. A lateral or longitudinal offset may reduce contact area between the terminal and flat cable, resulting in inefficient electrical conduction between the flat cable and the conductive element. In other cases, a pitch or roll offset (i.e., when two planar surfaces are non-parallel) may also reduce the contact area between the terminal and flat cable. The electrical connector assembly described herein describes various features, systems, and methods for creating intimate contact between the terminal and the flat cable.
The terminal(s) 104, the flat cable 102, and the stuffer 106 are insertable into the connector housing 101 through a first opening 140 located on the first end 126 of the connector housing 101. The CPA device 108 may be inserted into the connector housing 101 at channel 154 located at the first end 126 of the connector housing 101. In some embodiments, the stuffer 106 may include one or more alignment wings 170 configured to be received within an outboard recess 172 at the first end 126 of the connector housing (see e.g.,
In some embodiments, the connector housing 101 may include one or more features to ensure proper positioning of the terminal 104 seated within the connector housing 101. For instance, the connector housing 101 may include internal divider walls to ensure proper lateral position and orientation of the terminal 104 seated within the connector housing 101, and/or the connector housing 101 may include one or more alignment channels to receive one or more alignment tabs located on the terminal 104 to ensure proper positioning and alignment. In some embodiments, the connector housing 101 may include features/elements configured to ensure proper position of the flat cable 102 therein. For instance, the flat cable 102 may lay flush against a planar surface disposed within connector housing 101. In some embodiments, a ridge may run across the planar surface to provide a backstop for the flat cable 102, i.e., to ensure the flat cable is inserted into the correct depth of the connector housing. In some embodiments, the connector housing may include outboard channels to receive the lateral sides of the flat cable 102 therein to ensure proper lateral alignment and orientation of the flat cable 102 within the connector housing 101. Proper positioning of the flat cable 102 and the terminal 104 is important for ensuring intimate contact between the two components. For instance, a lateral or longitudinal offset may reduce contact area between the terminal 104 and flat cable 102, resulting in inefficient electrical conduction between the flat cable 102 and the conductive element. In other cases, a pitch or roll offset (i.e., when two planar surfaces are non-parallel) may also reduce the contact area between the terminal 104 and flat cable 102.
In some embodiments, the stuffer 106 may provide forward/rearward alignment of the terminal 104 within the connector housing 101. For instance, the stuffer 106 may abut the terminal 104 to urge the terminal 104 into a fully-seated position within the connector housing. In some embodiments, the stuffer 106 may abut the flat cable 102 to pinch the flat cable 102 against the planar surface 140 of the connector housing. The stuffer 106 may urge the terminal 104 toward the flat cable 102 to create intimate contact between the terminal 104 and the flat cable 102. In some embodiments, the stuffer 106 may provide lock assurance, as the locking detent 144 may engage the connector housing 101 to lock the stuffer 106 in-place.
In some embodiments, the CPA device 108 may be inserted into a channel 154 located on the connector housing 101. The CPA device 108 may provide lock assurance by forcing contact between the locking detent 144 and the connector housing 101 (i.e., preventing the locking detent 144 from disengaging the connector housing 101). In some embodiments, the CPA device 108 may provide connection assurance between the connector housing 101 and a mating device (see e.g.,
As illustrated in
In some embodiments, the stuffer 106 may include an elongate member 112 configured to engage and/or abut a surface 116 of the terminal 104. Thus, the stuffer 106 may urge the terminal 104 to be fully seated within the connector housing 101, providing orientation and alignment assurance. The stuffer 106 may include a locking detent 144 engageable with a locking surface 145 of the deflectable biasing member 156. The locking detent 144 may engage the locking surface 145 to lock the stuffer 106 in place, i.e., prevent the stuffer 106 from moving toward the first end 126 of the connector housing 101. The deflectable biasing member 156 may flex away from the planar surface 142 as the stuffer 106 is inserted into the connector housing 101, i.e., the locking detent 144 may urge the deflectable biasing member 156 as the stuffer 106 is slid into place. When the locking detent 144 passes by the locking surface 145 of the deflectable biasing member 156, the deflectable biasing member 156 may be biased to return toward the planar surface 142 (i.e., the deflectable biasing member 156 may be biased to deflect in a direction toward the planar surface 142). In some embodiments, the stuffer 106 may include a stop 184 configured to abut a surface in the connector housing 101 to prevent the stuffer 106 from moving toward the second end 128 of the connector housing 101, while in some embodiments, the contact between the elongate member 112 and the surface 116 of the terminal 104 prevents the stuffer 106 from moving toward the second end 128.
In some embodiments, the stuffer may include a ridge 160 configured to engage with the flat cable 102 in an area adjacent to the first end 126 of the connector housing 101. In some embodiments, the ridge 160 may provide a force against the flat cable 102 to pinch the flat cable 102 between the stuffer 106 and the planar surface 142. In some embodiments, the ridge 160 may include a second planar surface 118 to lay flush against the flat cable 102. The force between the stuffer 106 and the flat cable 102 may provide strain relief for the flat cable 102. In some embodiments, the force between the stuffer 106 and the flat cable 102 may provide connection assurance between the flat cable 102 and the terminal 104, as the flat cable 102 may be secured in-place by the pinch force between the stuffer 106 and the flat cable 102.
In some embodiments, the stuffer 106 may include an engagement surface 164 configured to engage the tanged portion 132 of the terminal 104. The engagement surface 164 of the stuffer 106 may urge the tanged portion 132 of the terminal 104 toward the flat cable 102. Thus, the conductive member 136 is forced against the flat cable 102, establishing an intimate connection between the conductive member 136 and the flat cable 102. In some embodiments, urging the conductive member 136 toward the flat cable 102 may increase a conductive contact area between the two components.
The apertures 120 enable the flat cable 102 to be welded to the terminal 104 (or vice-versa) after the terminal 104 and flat cable 102 are inserted into the electrical connector assembly 100. Such configuration may be beneficial, as the insertion of the terminal 104, the flat cable 102, and the stuffer 106 may ensure intimate contact between the first conductive contact region 110 to the second conductive contact region 105 (see e.g.,
In some embodiments, the assembly process may be partially or entirely automated, i.e., the components may be secured together without human intervention. For example, the terminal 104 may be inserted through the first opening 140 of the connector housing 101 via a robotic implement. The alignment tabs 174 may ensure the proper alignment of the terminal 104 within the connector housing. The flat cable 102 may be inserted through the first opening 140 via a robotic implement. The ridge 168 and/or the outboard channel 182 may guide the flat cable 102 to the proper positioning within the connector housing 101 to ensure the first conductive contact region 105 is aligned with the second conductive contact region 110. After the flat cable 102 and the terminal 104 are inserted within the connector housing 101, the stuffer 106 may be inserted through the first opening 140 via a robotic implement. The mating of the outboard recess 172 and the alignment wing 170 of the stuffer 106 may guide the insertion of the stuffer 106 to the proper location within the connector housing 101. The stuffer 106 may urge the conductive member 136 of the terminal 104 toward the first conductive contact region 110 of the flat cable 102 to create intimate contact. In some embodiments, after intimate contact is created between the first conductive contact region 110 and the second conductive contact region 105, the welding element 122 may weld the first conductive contact region 110 to the second conductive contact region 105 through the aperture 120. In some embodiments, the welding element 122 may be automated. Thus, insertion of the terminal 104, the flat cable 102, and the stuffer 106 prior to welding the terminal 104 to the flat cable 102 may simplify the assembly process by providing built-in, intimate contact features for the first conductive contact region 110 and the second conductive contact region 105. If, for example, the terminal 104 was welded to the flat cable 102 prior to installation into the connector housing 101, additional steps may be required to guarantee intimate contact between the terminal 104 and the flat cable 102 prior to the welding step.
In some embodiments, the stuffer 106 may ensure that the terminal 104 is fully-seated within the connector housing 101, as the elongate member 112 urges the surface 116 of the terminal 104 toward the second end 128 of the connector housing 101. The stuffer 106 may contact the conductive member 136 of the terminal 104, and in some cases, the tanged portion 132 of the conductive member 136, to urge the conductive member 136 against the flat cable 102. The stuffer 106 may include the ridge 160 configured to engage the flat cable 102 and pinch the flat cable 102 between the ridge 160 and the planar surface 142.
The connector housing 101 may include a channel 154 (i.e., a CPA channel) located at the first end 126 adjacent to the first opening 140. The channel 154 may be configured to receive the CPA device 108 therein and may provide an engagement surface to engage with the outboard arm 186, the locking surface 188, and/or the deflectable bowed surface 188. The connector housing 101 may include a locking recess 150 configured to receive the locking tab 148 therein, and selectively lock (or secure) the CPA device 108 to the connector housing 101. The connector housing 101 may include a deflectable release 152 configured to release the locking tab 148 from the locking recess 150. In some embodiments, the CPA device 108 may provide a tactile and/or auditory feedback when fully inserted into the connector housing 101.
The CPA device 108 may abut the deflectable biasing member 156, and in some embodiments, the CPA device 108 may prevent the biasing member 156 from deflecting away from the stuffer 106. Thus, the deflectable biasing member 156 including the locking surface 145 may be further secured by the CPA device 108, preventing the locking detent 144 of the stuffer 106 from disengaging the locking surface 145. In other words, the CPA device 108 may provide connection assurance for the stuffer 106, and since the stuffer provides connection assurance for the flat cable 102 and the terminal 104, the CPA device 108 thereby may provide connection assurance for the terminal 104 and the flat cable 102.
At step 204, the method 200 may include providing a welding element. The welding element may include a laser emitting device, an arc welding device, a solder iron, or any other welding device commonly known in the art. The welding element may include any and/or all features of the welding element 122 described in any of
At step 206, the method 200 may include inserting the terminal into the connector housing. The terminal may include any and/or all features of the terminal 104 (and the terminal 104′) described in any of
At step 208, the method 200 may include inserting the flat cable into the connector housing. The flat cable may include any and/or all features of the flat cable 102 described in any of
At step 210, the method 200 may include creating a mechanical contact between a first conductive contact region of the flat cable and a second conductive contact region of the terminal. The first and second conductive contact regions may include any and/or all features of the first conductive contact region 110 and the second conductive contact region 105. In some embodiments, step 210 may include inserting a stuffer (e.g., the stuffer 106) through the first opening 140 of the connector housing 101. Inserting the stuffer 106 through the first opening 140 may mechanically deflect the second conductive contact region 105 of the terminal 104 toward the first conductive contact region 110 of the flat cable 102.
At step 212, the method 200 may include welding the first and second contact regions through an aperture. The aperture may include any and/or all features of the aperture 120 described in any of
Other embodiments of the present disclosure are possible. Although the description above contains much specificity, these should not be construed as limiting the scope of the disclosure, but as merely providing illustrations of some of the presently preferred embodiments of this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of this disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form various embodiments. Thus, it is intended that the scope of at least some of the present disclosure should not be limited by the particular disclosed embodiments described above.
Thus the scope of this disclosure should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present disclosure fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present disclosure, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.
The foregoing description of various preferred embodiments of the disclosure have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise embodiments, and obviously many modifications and variations are possible in light of the above teaching. The example embodiments, as described above, were chosen and described in order to best explain the principles of the disclosure and its practical application to thereby enable others skilled in the art to best utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the claims appended hereto
Various examples have been described. These and other examples are within the scope of the following claims.
This application claims benefit of priority to U.S. Provisional Patent Application No. 63/403,436 filed on Sep. 2, 2022, the entire disclosure of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63403436 | Sep 2022 | US |
