EP0392108B1 - Housing assembly in combination with a flat power cable connector - Google Patents

Description

• The present invention relates to the field of electrical connectors and more particularly to terminating flat power cables.
• Flat power cable is entering commercial use for transmitting electrical power of for example 75 amperes nominal, and includes a flat conductor one inch wide and about 0.0508 cm (0.020 inches) thick with an extruded insulated coating of about 0.01016 cm to 0.02032 cm (0.004 to 0.008 inches) thick over each surface with the cable having a total thickness averaging about 0.08636 cm (0.034 inches). Also entering commercial acceptance is a dual conductor flat cable, wherein a pair of parallel spaced coplanar flat conductor strips having insulation extruded therearound define power and return paths for electrical power transmission. It is desired to provide housing means for a connector having terminals terminated to single or dual conductor flat power cable.
• It is also desired to provide a means for cable strain relief included by the connector.
• It is further desirable for the connector housing to provide means for limiting axial and vertical movement of the terminals within the housing.
• The present invention consists in a housing assembly in combination with a flat power cable, as defined inclaim 1.
• There is disclosed in Figures 1 to 16b and the description relating thereto of EP-A-0 342 868, which are comprised in the state of the art by virtue of Article 54(3) EPC, a housing assembly for housing the terminated end of a flat wide power cable, the cable being of the type having one or two flat relatively wide conductors therein with a pair of corresponding relatively wide terminals terminated onto the cable end and each having a nominal vertical height, the assembly having a housing having cavities in communication with the rearward end of the housing and generally dimensioned slightly larger cross-sectionally than the terminals, in which cavities the terminals are to be disposed upon insertion thereinto until engaging rearwardly facing stop surfaces along the cavities with contact sections of the terminals extending through forward passageways of the housing to be exposed along the mating face for mating with corresponding contact sections of another electrical article, the housing also having forwardly facing stop means for terminal retention.
• WO88/07775 discloses a housing assembly for housing terminations on ends of leads, the housing assembly having cavities in which the terminals are disposed with contact sections of the terminals exposed along a mating face for mating with corresponding contact sections of another electrical article, the housing assembly comprising a housing which is an integral member, with respective cavities in communication with the rearward end of the housing for receiving the terminals when inserted thereinto after the terminals have been terminated onto the ends of leads, and having rearwardly facing stop surfaces providing forward stops for the terminals and further including forward passageways through which the contact sections extend to the mating face and rearward members, securable onto the rearward end of the housing after insertion of the terminals into the housing cavities. The rearward members define forwardly facing stop surfaces and retain the terminals within the housing cavities.
• There is disclosed herein a housing means for a pair of transition adapter terminals terminated adjacent each other to an end of flat power cable, to define an electrical connector. The pair of terminals and the housing therefor may be used with single conductor flat power cable but are especially suitable for terminating dual conductor flat power cable. The terminals include contact sections extending forwardly from the cable end and extending forwardly from or otherwise exposed along the mating face of the housing for electrical connection with corresponding contact means of another electrical article such as another cable connector, a header mounted on a printed circuit board, terminal posts of a power supply, or a bus bar.
• Each terminal is of the type having a pair of opposed plate sections transversely across each of which are an array of shearing wave shapes alternating with relief recesses, so that when the pair of plate sections disposed against major surfaces of the flat cable at an end thereof are pressed together and against the cable therebetween, the arrays of shearing wave shapes cooperate to shear the conductor of the flat cable into a plurality of strips which remain integral with the cable. The wave shapes also extrude the newly sheared conductor strips into the opposing relief recesses so that newly sheared conductor edges are moved adjacent electrical engagement surfaces defined by the vertical side edges of the adjacent shearing wave shapes forming electrical connections of the adapter terminals with the flat cable conductors.
• The pair of plate sections of each terminal both extend forwardly from a rearward cable-receiving terminal end where they coextend forwardly at a slight angle from a pair of bight sections spaced laterally apart defining a cable-receiving slot therebetween of known transverse width. Tab-shaped portions are formed on the end section of the cable and are inserted through the cable-receiving slots of the terminals and are disposed between upper and lower plate sections of each terminal. The upper and lower plate sections of each pair are pressed respectively together by being rotated about the bight sections which act as integral hinges, so that the shearing wave shapes shear and extrude strips of the conductor (or conductors) of the cable forming a termination of the terminals to the cable.
• The two tab-shaped cable portions fit through the terminal slots with no more than a slight clearance with the inside edges of the pair of bight sections of each terminal. More importantly, the exposed axial conductor edges are formed precisely to be adjacent outwardly facing edges of the inner ones of the bight sections of the respective terminals. When the terminal plate sections are pressed together terminating the cable, the inner bight section already at least adjacent the conductor edge along the cable slot is deformed slightly against the conductor edge thereby biting into the metal, while the outer bight section is deformed slightly against and into the insulative coating along the adjacent lateral outer edge of the cable, thus gripping the tab-shaped cable portions after termination to act as stop mechanisms against axial movement of the terminals with respect to the cable and relieving stress on the terminations.
• The terminals terminated to the tab-shaped cable portions are insertable into respective openings at the rearward end of a housing member until the terminals are disposed within respective cavities and the contact sections are disposed appropriately along the housing mating face. The housing member of the connector of the present invention is preferably molded as an integral member to precisely define upper and lower pairs of terminal-proximate ledges of precisely fixed spacing. The pairs of ledges maintain each of the terminals closely positioned vertically within their respective cavities to assist in minimizing detrimental effects of vibration on the terminations and are assisted in that function by a central rib between the cavities joining the upper and lower housing cover portions. A strain relief member is then securable to the rearward housing end to define a cable exit, and includes rearward stop surfaces to maintain the terminals properly positioned axially within the housing, maintaining the contact sections in position axially to enhance wear resistance of the contact surfaces by minimizing axial movement thereof.
• The cable strain relief member of the connector of the present invention is preferably integrally molded of plastic and bifurcated having upper and lower transverse struts joined at one lateral end, to be inserted over the flat cable from one side thereof after termination by the terminals. The member has a pair of latch arms each extending forwardly from a respective lateral end, which latchingly engage the housing when moved forwardly along the cable and against the rearward end of the housing. One of the latch arms is an integral member at the integrally joined lateral end while the other is split horizontally comprising upper and lower arm sections respectively extending forwardly from the lateral ends of the upper and lower struts at the split lateral end. When latched upper and lower arm sections are firmly held together vertically by the latching recess of the housing, and the strain relief member then closely fits against the flat cable disposed between the upper and lower struts, with curved cable-proximate edges to maintain the integrity of the cable insulation during handling and in the event the cable is bent or stressed vertically into a perpendicular orientation.
• It is an objective of the present invention to provide a housing for terminals terminated onto an end of flat power cable.
• It is also an objective for such a housing to accommodate a system of terminals simultaneously for either single or dual conductor flat power cable.
• It is a further objective to provide a housing which is adapted to secure the terminals substantially against vertical movement therewithin and to secure the terminals substantially against axial movement therewithin.
• It is yet a further objective to provide a strain relief member securable to the rearward end of an integral housing after the terminated cable end is received into the housing from rearwardly thereof.
• It is still further an objective to provide such a strain relief member which is an integral member latchable to the housing and which snugly fits about the flat cable.
• Embodiments of the housing and strain relief members will now be described, by way of example, with reference to the accompanying drawings, in which:
• FIGURE 1 is a perspective view of the connector of an embodiment of the present invention, and a connector matable therewith, with the terminated flat cable exploded from the housing and a strain relief member exploded from the connector;
• FIGURE 2 is a perspective view of the housing and strain relief member of Figure 1 from rearwardly thereof;
• FIGURE 3 is a longitudinal section view through the housing taken along lines 3-3 of Figure 2;
• FIGURE 4 is a perspective view of the terminals about to receive the prepared cable end for termination thereto, and showing an alternate type of contact section on the terminals;
• FIGURES 5A and 5B illustrate placing terminals on the cable end prior to termination, with insert members of the terminals not shown, and where the flat cable is a single conductor type and the terminals being integral across the contact sections;
• FIGURES 6 and 7 illustrate the terminals of Figure 1 being terminated to the cable end;
• FIGURES 8 and 9 are section views taken along lines 8-8 and 9-9 of Figures 6 and 7 respectively, showing the terminals gripping the side edges of the cable end upon termination;
• FIGURES 10 through 12 are plan section views of the mating connectors of Figure 1 prior to securing the respective terminals in the housings, after terminal securing, and after connector mating, respectively;
• FIGURES 13 and 14 are elevation section views of the connectors of Figures 11 and 12 taken along lines 13-13 and 14-14 respectively thereof, unmated and mated; and
• FIGURES 15 and 16 illustrate separate terminals and individual housings and strain relief members for terminating dual conductor flat cable for relative axial spacing of the connectors, before and after insertion of the terminals into the respective housings.
• Connector 10 of Figure 1 includes ahousing member 12 and rearward cable exit orstrain relief member 14, adapted to house a pair ofterminals 16 terminated ontoflat power cable 18.Connector 20 is matable withconnector 10 and is adapted to house a corresponding pair ofterminals 22 which are shown to includepost sections 24 extending rearwardly fromhousing 26 for insertion into corresponding plated through-holes of a printed circuit board (not shown).Terminals 22 also are shown having springarm contact sections 28 at forward ends thereof matable withsplines 30 at forward ends ofterminals 16, whenconnectors 10 and 20 are mated.Housing 12 includes a plurality offorward passageways 32 in communication withmating face 34 within each of which is disposed aspline 30 afterterminals 16 are inserted intohousing member 12 from rearwardend 36.Housing 26 ofconnector 20 includes alarge cavity 38 within which are disposedspring arms 28, andlarge cavity 38 is adapted to receive thereintoforward section 40 ofhousing 12 ofconnector 10 upon mating, withspring arms 28 received withinpassageways 32 to electrically engagerespective splines 30.Housing 12 is shown having a pair oflatch arms 42 along sides thereof which ride over and latchingly engage a pair ofcorresponding latching projections 44 ofhousing 26 to secure the connectors together.Latch arms 42 are shown having rearward grippingportions 46 deflectable inwardly to facilitate delatching fromprojections 44 upon connector unmating.
• Referring to Figures 1 and 2, afterterminals 16 oncable 18 are inserted intorearward housing end 36,strain relief member 14 is insertable acrossflat cable 18 fromlateral edge 48 and then movable forwardly therealong to latch securely tohousing member 12 along rearwardend 36.Strain relief member 14 includes upper andlower struts 50,52 extending laterally fromintegral section 54 spaced slightly apart forcable 18 eventually to be disposed therebetween. Atlateral end 56 includingintegral section 54,first latch arm 58 extends forwardly to inwardly directedlatching projection 60. At lateral end 62 a pair ofsecond latch arms 64 extend forwardly from ends of upper andlower struts 50,52 to inwardly directedlatching projections 66 which will cooperate as a single latch arm during latching toconnector housing 12.Housing member 12 includes near rearwardend 36 and along outer surfaces 68 a pair oflatching recesses 70 in channels defined between upper and lower channel wall surfaces 71, for receivingthereinto latching projections 60,66,66 whenstrain relief member 14 is secured tohousing member 12.
• Upon assembly tohousing member 12 cablestrain relief member 14 defines a cable exit orslot 72 between facingsurfaces 74,76 of upper andlower struts 50,52 with roundedrearward corners 78 and betweenside walls 80,82,82 nearlateral ends 56,62 respectively. The distance betweenside walls 80,82,82 is preferably selected to be slightly less than the nominal width ofcable 18 to generate a slight interference fit width wise after connector assembly. Further it is preferred that after connectorassembly facing surfaces 74,76 of upper andlower struts 50,52 clamp against upper and lowermajor surfaces 84,86 ofcable 18. Forwardly facingsurfaces 88 ofstruts 50,52 shown in Figure 1 will act as rearward limits or stops engageable byterminals 16 after connector assembly;rounded recesses 90 insurfaces 88 are shown within which rearwardmost portions ofterminals 16 are received (Figures 13 and 14).
• Referring to Figures 2 and 3, a pair oflarge cavities 92 extend forwardly fromrearward housing end 36 to rearwardly facingstop surfaces 93, to receiveterminals 16 inserted thereinto. Pairs of upper andlower ledges 94 are defined axially along both sides of eachcavity 92 between whichterminals 16 will be disposed, with the distance between the facing ledge surfaces precisely selected so that afterconnector assembly terminals 16 will be allowed little vertical movement, if any, but allowing for some tolerance in the eventual height ofterminals 16 which are terminated to cable 18 (Figures 13 and 14).Housing member 12 being integrally molded allows the distance between facing ledge surfaces to be precisely controlled.Vertical barrier wall 96 betweencavities 92 disallows upper and lower cover sections 98,100 ofhousing 12 from slight spreading and thus maintains the distance between facing ledge surfaces of the inner pairs thereof.
• Terminals 16 include stamped and formedadapter members 102 disposed immediately against cable surfaces 84,86, and also preferably includeinsert members 104 secured along cable-remote surfaces ofadapter members 102 and being of high copper content which establish gas-tight electrical engagement with sheared edges of the cable conductors after termination. Figure 4 illustrates a pair ofadapter members 106 having blade-like contact sections 108 of the type suitable for termination to terminal posts of a power supply; it is preferred that the terminals include insert members but such inserts are not shown in order to assist in illustrating the method of termination.Cable 18 includes two parallel spaced coplanarflat conductor members 10 therein coated by an insulative covering which also defines amedial portion 112 between theconductors 110. As showncable 18 is prepared by cutting anaxial slot 114 rearwardly from the cable end along the cable centerline, slot 114 having a selected width, thereby defining a pair of tab-shapedcable portions 116. Rearward ends 118 ofadapter members 106 include a pair of bight sections 120,122 which join upper and lower plate sections 124,126 ofadapter members 106.
• Referring now to Figures 5A and 5B, an alternate embodiment ofadapter member 128 is shown having twoadapter sections 130 each having a cable-receiving slot between pairs of bight sections 132,134.Adapter member 128 is integral acrosscontact section 136 containingsplines 138 and is suitable for terminatingsingle conductor cable 140 which has been prepared similarly tocable 18 of Figure 4 to have a pair of tab-shapedcable portions 142. Tab-shapedcable portions 142 are inserted into and through the cable-receiving slots untilcable portions 142 are disposed between pairs of upper and lower plate sections 144,146. Defined transversely across upper and lower plate sections 144,146 are arrays of alternating shearing wave shapes 148 andrelief recesses 150, withwave shapes 148 extending toward upper and lower major surfaces of the flat cable.
• In Figures 6 and 7 arepresentative terminal 16 is shown having anadapter member 102 and upper andlower insert members 104a,104b, with a tab-shapedcable portion 152 extending through cable-receivingslot 154 and disposed between upper and lower plate sections 156,158 ofadapter member 102. Crests 160,162 of shearing wave shapes 164,166 of upper and lower plate sections 156,158 are shown against cable surfaces 84,86 prior to termination in Figure 6; in Figure 7, wave shapes 164,166 have sheared the conductor ofcable 18 and have extruded the thus-sheared conductor strips 168 into the opposing relief recesses 170,172 to define alternating and interlocking upper and lower wave joints 174,176 disposed inrespective apertures 178 ofinsert members 104. In Figure 7 sheared conductor edges are disposed adjacent and in electrical engagement with the vertical wall surfaces simultaneously defining the sides of wave shapes 180 and longitudinal side walls ofapertures 178 adjacent and alternating withwave shapes 180 transversely across upper andlower insert members 104a,104b. The wave joints may preferably be split by staking, and the insert members also staked along outwardly facing surfaces of wave shapes 180 to enhance the gas-tight nature of the electrical connections between the insert members and the sheared conductor edges by imparting stored energy in the wave joints.
• In Figures 8 and 9 can be seen the gripping of lateral edges of the tab-shaped conductor portions before and after termination ofterminals 16 thereto. Inner and outer bight sections 182,184 define cable-receivingslot 154 between facing edges 186,188 thereof.Cable 18 has been prepared as in Figure 4 by cutting aslot 190 along the cable centerline, thereby shearingconductor 192 forming asheared edge 194.Cable insulation 196 extends alonglateral cable edge 198 and also definesmedial strip 200 between the pair of conductors. When upper and lower plate sections of the adapter member are pressed together as in Figure 7, the metal of the bight sections 182,184 is deformed slightly and protrudes simultaneously against theconductor edge 194 andlateral cable edge 198 thereby biting into the metal ofconductor 192 at 202 and compressing theinsulation material 196 at 204 to grip the tab-shapedcable portion 152 and comprise an axial stop forterminal 16 alongcable 18.
• Figures 10 to 12 illustrate the assembly ofconnectors 10 and 20.Terminals 16 have been terminated to tab-shapedcable portions 152 including splitting the wave joints as indicated at 206 and staking the inserts between the wave joints as indicated at 208. Cablestrain relief member 14 has been inserted overcable 18 fromlateral edge 48 in Figure 10. In Figure 11terminals 16 have been inserted intocavities 92 ofhousing member 12 withsplines 30 withinpassageways 32, andstrain relief member 14 has been latched tohousing member 12 by latchingprojections 66 in latchingrecesses 70;terminals 22 have been secured inhousing member 26 ofconnector 20 withcontact sections 28 arrayed acrosscavity 38 and postsections 24 extending outwardly fromhousing member 26. In Figure 12connectors 10 and 20 are shown latched and mated together, with latching surfaces 210,212 oflatch arms 42 andprojections 44 having a slight reverse angle for vibration resistance;forward section 40 ofhousing member 12 has been received withincavity 38 ofhousing member 26 and with springarm contact sections 28 ofterminals 22 electrically engaged withsplines 30 ofterminals 16, alternating upwardly and downwardly across the terminals.
• Figures 13 and 14show connectors 10 and 20 being mated, with a downwardly angled spline 30a and an upwardly deflectablespring contact arm 28a electrically engageable together. Cablestrain relief member 14 is shown latched in place defining the cable exit withcable 18 clamped between facingsurfaces 74,76 of upper andlower struts 50,52 and abight section 184 of terminal 16 disposed in arecess 90.
• In Figures 15 and 16 are shown an alternate arrangement wherein terminals 250,252 are terminated to ends of respective cable portions 254,256 containing individual conductors of adual conductor cable 258.Individual housing members 260 are shown for terminals 250,252, with individual cablestrain relief members 262 shown to be placed and latched to rearward ends ofhousing members 260. The arrangement shown accommodates the desire to space the connectors 264,266 apart for the power and return paths established by the individual conductors of the cable.

Claims (10)

1. A housing assembly in combination with a flat power cable (18) having one or two flat cable conductors therein and being of given substantial width, the, or each, cable conductor having an end terminated to terminal (16) of a width corresponding to said given width, the, or each, terminal (16) having a given vertical height, the housing assembly comprising a housing (23) which is an integral member having at least one cavity (92) in communication with a rearward end (36) of the housing (12), for receiving a said terminal (16) and being of slightly larger cross-section than said terminal (16) and of sufficient width to receive it, the, or each cavity (92) having therein a rearwardly facing stop surface (93) for engaging said terminal to limit its insertion into the cavity (92) by way of said rearward end (36) of the housing (12), so that contact sections (30) of the terminal (16) extend through forward passageways (32) of the housing (12) to be exposed along a mating face (34) thereof for mating with corresponding contact sections (28) of another electrical article; the housing assembly further comprising a rearward member (14) securable onto the rearward end (36) of the housing (12) after insertion of the, or each terminal (16) into its cavity (92), the rearward member (14) being of an area corresponding to the cross sectional area of the cavity, or of each of said cavities (92), and the rearward member (14) defining a slot (72) between upper and lower strut members (50,52) thereof, the slot (72) having a width about equal to said given width of the flat cable (18) and a height about equal to the thickness of the flat cable (18) after the rearward member (14) has been secured to the rearward end (36) of the housing (12), and the rearward member (14) defining a forwardly facing stop surface (88) corresponding to a rearwardly facing stop surface of the, or each, terminal (16), whereby the rearward member (14) retains the, or each, terminal (16) within its housing cavity (92), with the flat cable (18) extending through the slot (72) of the rearward member (14), and provides dielectric material closing the rearward housing end (36) rearwardly from the termination of the, or each terminal (16) to the flat cable (18), thereby protecting the termination between the cable (18) and the, or each, terminal (16) from cable torque relative to the housing (12).
2. A housing assembly as set forth in claim 1 further characterized in that said rearward member (14) is bifurcated with said upper and lower struts (50,52) being integrally joined at a joint (54) at a first lateral end (56) and separated at a second lateral end (62), whereby the rearward member (14) is adapted to be inserted over the flat cable (18) from a lateral edge (48) thereof with said upper and lower struts (50,52) passing over and under upper and lower major surfaces (84,86) of the flat cable (18) rearwardly of the terminals (16) terminated to an end of the flat cable (18).
3. A housing assembly as set forth in claim 2 further characterized in that said rearward member (14) includes a first latch arm (58) extending forwardly from said first lateral end (56) and including first latching means (60) at a forward end of said first latch arm (58), and further includes second latch arms (64) coextending forwardly from said upper and lower struts (50,52) at said second lateral end (62) and having second latch means (66) at respective forward ends thereof, said second latch arms (64) comprising a cooperable latch arm pair opposed from said first latch arm (58), and said housing member (12) including corresponding latching means (70) along side walls (68) thereof proximate said rearward end (36) adapted to establish latching engagement with said first and second latching means (60,66) of said first latch arm (58) and cooperable latch arm pair (64) respectively when said rearward member (14) is urged axially forwardly along the flat cable (18) and against said rearward housing end (36), securing said rearward member (14) to said housing member (12) and retaining said terminals (16) in said housing member (12).
4. A housing assembly as set forth in claim 3 further characterized in that one of said corresponding latching means (70) is adapted to hold said second latch arms (64) of said cooperable latch arm pair after latching against movement relatively apart.
5. A housing assembly as set forth in claim 3 further characterized in that said first and second latching means (60,66) comprise latching projections (60,66) extending relatively toward each other and define rearwardly facing latching surfaces, and said corresponding latching means (70) comprise laterally outwardly facing latching recesses (70) adapted to receive said latching projections (60,66) thereinto upon latching and defining forwardly facing latching surfaces corresponding to said rearwardly facing latching surfaces to latchingly secure said rearward member (14) to said housing member (12).
6. A housing assembly as set forth in claim 5 further characterized in that said rearwardly facing latching surfaces are slightly angled outwardly and said forwardly facing latching surfaces are slightly angled inwardly, whereby the latching system defined by the rearward member (14) and the housing member (12) is adapted to hold the latch arms (58,64,64) relatively toward the side surfaces (68) and to thereby resist unlatching upon stress applied by the terminated flat cable urging said rearward member (14) rearwardly from said housing member (12).
7. A housing assembly as set forth in claim 2 further characterized in that said cable exit (72) is defined by facing surfaces (74,76) of said upper and lower struts (50,52) spaced to abut the upper and lower major surfaces (84,86) of the flat cable (18) after assembly, and by inwardly facing surfaces (80) defined on said integral joint (54) at said first lateral end (56) and on respective second lateral ends (82) of said upper and lower struts (50,52) after said rearward member (14) is secured to said housing member (12), which are spaced to abut the lateral edges of the flat cable (18) after assembly.
8. A housing assembly as set forth in claim 7 further characterized in that rearward edges (78) of said facing surfaces (74,76) of said upper and lower struts (50,52) are rounded.
9. A housing assembly as set forth in claim 1 for said terminals comprising a pair of separate terminal members (16) terminated onto respective tab-shaped portions (152) of the flat cable, further characterized in that said cavities (92) comprise a pair of cavities (92) for respective ones of said pair of separate terminal members (16), said housing member (12) including a central barrier wall (96) between said pair of cavities (92) establishing insulative material between the separate terminals (16) after insertion thereof into said pair of cavities (92) and joining said upper and lower cover sections (98,100) of said housing member (12) midway thereof transversely, whereby the upper and lower cover sections (98,100) are held a fixed spacing apart transversely thereacross along said rearward end (36).
10. A housing assembly as set forth in claim 9 further characterized in that pairs of upper and lower ledges (94) are defined axially along inner surfaces of said upper and lower cover sections (98,100) defining said pair of cavities (92) and adjacent upper and lower surfaces of the terminals (16) after insertion thereof into said cavities (92), said ledge pairs (94) being disposed at both lateral ends of each of said pair of cavities (92), upper and lower ones of each of said pair of ledges (94) having facing surfaces spaced apart a precise distance approximately corresponding to the nominal vertical height of each of the terminals (16) of said pair, whereby the housing member (12) maintains an assured effective vertical height to the respective cavities (92) and vertical movement of the separate terminals (16) is thereby closely limited.

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