Abstract:
A method for repairing a flatwire conductor is disclosed. The method includes aligning a cutting tool along the flatwire conductor at a first cut zone, cutting the flatwire along a transverse axis of the flatwire within the first cut zone, removing the cutting tool from the flatwire, aligning the cutting tool along the flatwire at a second cut zone, cutting the flatwire within the second cut zone, and removing the cutting tool and flatwire attached thereto to allow for replacement of the flatwire.

Description:
FIELD OF INVENTION  
         [0001]    The present invention relates to flatwire connections and devices and methods for repairing damages flatwire cables and associated connectors.  
         BACKGROUND ART  
         [0002]    In an ongoing effort to reduce cost and approve reliability in vehicle electrical and electronic systems, flatwire conductors having non-separable connections have gained wide spread use. One significant drawback in using non-separable connections in flatwire is the difficulty in servicing and repairing the flatwire.  
           [0003]    One prior art service method is to cut the flatwire, remove the defective/damaged portion, and attach a service part having a service connectors therein. Unfortunately, while this prior art method achieves its intended purpose, problems still exist. For example, current prior art methods typically dictate use of a service part which is different from the originally manufactured part adding additional design effort, manufacturing complexity, and cost. Moreover, current service methods are difficult to employ correctly within the tight confines of the vehicle structure. Consequently, additional damage to the vehicle system frequently occurs.  
           [0004]    Therefore, there exists a need for a new and improved service method and system for cutting flatwire and removing the damaged portions. The new and improved method should dispense with unique service parts and facilitate remanufacturing of the defective/damaged part as well as reuse of the service tool.  
         SUMMARY OF THE INVENTION  
         [0005]    In accordance with an aspect of the present invention, a method and apparatus for replacing flatwire in electrical systems is provided. The flatwire of the present invention includes design features to facilitate the method and apparatus used to repair the damaged or defective segment of the flatwire. For example, a cut-to-service area is provided in the flatwire having features to facilitate engagement and alignment of a cutting tool. The flatwire also includes two service connector attachment areas on opposing sides of the cut-to-service area. The service connector attachment areas allow a defective or damaged segment of the flatwire to be remanufactured and reused as a service part. Further, the service area design is symmetrical so that the flatwire segment on either side of the cut-to-service area may be removed if defective or damaged using an identical cutting tool and replaced with a replacement flatwire segment.  
           [0006]    In accordance with another aspect of the present invention, the service are of the flatwire allows replacement segments to be fabricated by cutting original equipment segments and attaching the service connectors at the service connector attachment areas.  
           [0007]    In accordance with another aspect of the present invention, a damaged or defective flatwire segment which has been removed and repaired is used as a replacement segment by attachment of a service connector.  
           [0008]    In another aspect of the present invention, a cutting tool is provided having features for engaging and aligning with the flatwire cut-to-service area to ensure that cutting occurs at the correct location and orientation.  
           [0009]    In yet another aspect of the present invention, a cutting tool is provided with a clamp for retaining a defective or damaged flatwire segment on the cutting tool during and after cutting.  
           [0010]    In yet another aspect of the present invention, a cutting tool having a symmetrical design for cutting defective or damaged flatwire segments on either side of a cut-to-service area using the same cutting tool is provided.  
           [0011]    In yet another aspect of the present invention, the cutting tool is provided with a cutting member and an indicator mark showing the segment of the flatwire to be removed.  
           [0012]    In still another aspect of the present invention, a service kit is provided having a cutting tool and a replacement flatwire segment wherein the flatwire segment has a service connector attached at a service connector attachment area.  
           [0013]    In still another aspect of the present invention, a method for servicing a flatwire electrical system is provided. The method includes identifying the defective or damaged flatwire segment, aligning the cutting tool at the cut-to-service area with the indicator mark pointing toward the flatwire segment to be removed, engaging the cutting tool clamp, actuating the cutting mechanism, removing the cutting tool and defective segment, and returning the cutting tool and defective segment to a remanufacturing center for repair or reuse.  
           [0014]    In yet another aspect of the present invention, a remanufacturing process is provided for processing the defective or damaged flatwire segments. The remanufacturing process includes receiving the defective or damaged flatwire segment having the cutting tool clamped thereon, removing the cutting tool, identifying the flatwire segment which is damaged or defective and repairing it, if possible, attaching a service connector to the repaired flatwire segment at the service connector location, and assembling a service kit using the returned cutting tool and remanufactured flatwire segment.  
           [0015]    Further aspects, features and advantages of the invention will become apparent from consideration of the following description and the appended claims when taken in connection with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a top view of a flatwire segment, in accordance with the present invention;  
         [0017]    [0017]FIGS. 2 a - 2   b  is front and side views of a cutting tool for cutting a flatwire segment, in accordance with the present invention; and  
         [0018]    [0018]FIGS. 3 a - 3   e  are perspective views of another embodiment of a cutting tool for cutting flatwire, in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]    Reference is now made to FIG. 1 wherein a flatwire electrical conduit  10  is illustrated, in accordance with the present invention. Flatwire  10  includes a plurality of conductors  12  for transmitting electrical signals to various parts of an electronic system. Typically, flatwire  10  is constructed with copper as the conductors  12 . The copper conductors are disposed on a flexible substrate such as MYLAR or similar material. MYLAR is available through Dupont Corporation of Delaware. MYLAR is a Dupont trade name for PET.  
         [0020]    In a preferred embodiment of the present invention a system and method is provided for servicing flatwire  10 . Typically, when flatwire  10  is damaged or is otherwise inoperable, portions of the flatwire  10  must be removed, and operable flatwire  10  portions must be inserted in place thereof. In accordance with an embodiment of the present invention, flatwire  10  includes a reconnect area  16  wherein conductors  12  are exposed. Reconnect area  16  is disposed along the flatwire  10  at desired intervals which may be regular or irregular intervals. Thus, when damage occurs in the flatwire  10  the portion of wire between the reconnect areas may be removed and a new or remanufactured operable portion of flatwire may be inserted in place thereof.  
         [0021]    In an embodiment of the present invention, features are present in flatwire  10  to facilitate cutting and replacement of an inoperable portion of the flatwire. Such features may include an alignment feature  18  and a cut starting notch  20 . The specific operation and use of alignment feature  18  and notch  20  will be described hereinafter with reference to a cutting tool  30  which is provided in another embodiment of the present invention.  
         [0022]    Referring now to FIG. 2 a , an embodiment of the cutting tool  30  is illustrated, in accordance with the present invention. FIG. 2 a  is a front view of cutting tool  30  illustrating a blade  32  fixedly mounted to a upper clamp member  34  for shearing and cutting flatwire  10 . Upper clamp portion  34  is directed towards a lower clamp portion  36  by pair of screws  38  which are received in cooperating threaded apertures  40 .  
         [0023]    Lower clamp portion  36  includes an alignment fixture  42  which is cooperatively configured to receive alignment feature  18  thereby ensuring the flatwire  10  and a cutting blade  32  is aligned within the reconnect area  16 . As will be seen in subsequent figures, lower clamp member  36  further includes a blade groove  44  for receiving the cutting blade  32 . Blade groove  44  has a depth sufficient to ensure that when the blade is lowered into and beyond flatwire  10  the edge of the blade does not crash into the bottom of the blade groove  34 .  
         [0024]    A cross-sectional view, at a location indicated in FIG. 2 a , of the flatwire  10  disposed within cutting tool  30  is illustrated in FIG. 2 b , in accordance with the present invention. In operation, flatwire  10  is positioned between upper clamp member  34  and lower clamp member  36  and alignment features  18  cooperate with alignment fixture  42  to ensure blade  32  is properly aligned with flatwire  10  and within the reconnect area  16  along a cut line  17 . An operator turns screws  38  forcing the upper clamp member  34  toward lower clamp member  36  and eventually causing cutting blade  36  to shear flatwire  10  along the cut line  17 . In an embodiment of the present invention the cutting tool  30  is placed on the inoperable or damaged portion of the flatwire  10 . Upon shearing of the flatwire  10 , the cutting tool  30  and the inoperable portion of flatwire  10  may be shipped to a facility for remanufacturing of replacement parts, such as replacement flatwire portions. Thus, the present invention provides a system and method for reusing the cutting tool and remanufacturing and/or refurbishing inoperable portions of the flatwire  10 .  
         [0025]    Referring now to FIG. 3 a  through FIG. 3 e , an alternative embodiment of cutting tool  30  is illustrated, in accordance with the present invention. Alternative cutting tool  30 ″ includes a top plate  80  shown in FIG. 3 a , and a bottom plate  100  shown in FIG. 3 d . Top plate  80  has a longitudinal slot  82  for receiving a guide pin  84 . Guide pin  84  is fixedly secured to top plate  80  and slideably guides a cutter block  86  for movement within slot  82 . Cutter block  86  includes a guide pin aperture  88  configured to receive guide pin  84  to facilitate cooperative movement of the cutter block  86  along guide pin  84 . Cutter block  86  further includes a cutting blade  90  fixedly secured to a bottom surface of cutter block  86 . Further, top plate  80  includes a pair of apertures  91  for receiving screws  92  (shown in FIG. 3 c ). Screws  92  are used to removeably attach the top plate  80  to bottom plate  100 , as will become apparent hereinafter.  
         [0026]    [0026]FIG. 3 c  is a bottom perspective view of top plate  80 . In addition to further illustrating cutter block  86 , cutting blade  90  and other features of top plate  80 , such as a pair of guide apertures  94  are illustrated. Guide apertures  94  cooperate with a pair of alignment pins  96  disposed on bottom plate  100 , as shown in FIG.  3   d , to align the top plate  80  with bottom plate  100 . Thus, the assembly of the top plate  80  onto the bottom plate  100  may be accomplished quickly and easily.  
         [0027]    With specific reference to FIG. 3 d , bottom plate  100  is further illustrated, in accordance with the present invention. A pair of threaded apertures  98  receive screws  92  for removeably securing top plate  80  to bottom plate  100 . A groove  99  is disposed longitudinally in bottom plate  100  for providing clearance for cutting blade  90 .  
         [0028]    In operation, alternative cutting tool  30 ″ is secured to flatwire  10 , as shown in FIG. 3 e . By aligning the top plate  80  over the bottom plate  100  and securing bottom plate  100  to top plate  80  using screws  92 . Cutter block  86  may then be slid longitudinally along guide pin  84  to cut flatwire  10  preferably within the reconnect area  16  and along cut line  17  (shown in FIG. 1). The resulting assembly, that is the second flatwire portion and attached cutting tool  30 ″, may be removed and sent to a facility equipped for recycling and/or remanufacturing flatwire  10 . A flatwire connector (not shown), as well known in the art, may be attached to the remaining flatwire at the reconnect area  16 . The flatwire connector may have a replacement flatwire portion, having a length equal to the flatwire portion that was removed.  
         [0029]    The present invention has many benefits and advantages over the prior art. For example, embodiments of the present invention provide a system and method for easily replacing damaged portions of a flatwire. Moreover, the present invention provides a system and method for recycling flatwire and flatwire cutting tools.  
         [0030]    The foregoing discussion discloses and describes a preferred embodiment of the invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that changes and modifications can be made to the invention without departing from the true spirit and fair scope of the invention as defined in the following claims.