Connector for flat cables

Abstract: An electrical connector has multiple pairs of penetrating first apertures (23) and second apertures (24) which are longitudinally formed from bottom (21) to top (22) of an insulated connector housing (20), and a cable insertion aperture (25) connecting with first aperture (23) and formed in the top ( 22). Each contact (40) has a beam-shaped contact unit (44) and a holder (46) projecting upward from base (41), and a solder tine (48) extending downward from the base (41). A contact point (45) elastically projects into cable insertion aperture (25). A probe for continuity checking can access contact (40) and holder (46) from second aperture (24).

Description: This invention relates to an electrical connector and, in particular, to a flat connector which has multiple contacts connected to the end of a flexible flat cable (FFC). FFCs have superior utility and operability because they arrange multiple leads densely and are very flexible; consequently, they are widely used in small electronic devices such as CD players, video cameras, and small business (office) devices such as copiers and fax machines. Japanese Utility Model 3-22869 and Japanese Patent Application 59-23482, for example, disclose conventional connectors for FFCs. Such conventional FFC connectors generally include hook-shaped contacts or a single beam-shaped contact and the FFC end is overlapped with a slider's insulated tongue inside an insulated housing and is thereby connected and secured. Similarly, EP-A-0 320 250 describes a connector for connecting an FFC to a printed circuit board, the connector including forked terminal contacts having contact arms for contacting conductive areas of the FFC, when it is inserted into the connector housing, and a plug wedge or slider for wedging the FFC in the housing. However, such conventional FFC connectors inevitably are large due to the contact shape and use of a slider, so that it is impossible or extremely difficult for them to meet the demand for miniaturization in the latest electronic devices. Also, it is difficult for such conventional FFC connectors adequately to handle multiple contacts if there are about forty contacts, for example. Furthermore, it is hard to do an electrical continuity check on whether or not the FFC leads touch correctly. Prior art Figures 9-10 of the accompanying drawings show another conventional example of an FFC connector 1. Figure 9 is a top view, Figure 10 is a cross-section along line B-B, and Figure 11 shows the end of a commonly known FFC used in the FFC connector 1. Long thin cable insertion groove 3 is formed from the top towards the bottom of the insulated housing of FFC connector 1 and multiple contact-receiving apertures 4a-4b are formed along cable insertion groove 3. Furthermore, key 5 is formed by, for example, unitary molding to cross cable insertion groove 3 at a position which is off-center relative to the cable insertion groove 3. Additionally, as shown in Figure 10, contacts 6 are pressed into each contact-receiving aperture 4a-4b from the bottom of insulated housing 2. The single-beam contact arm 7 of contact 6 is inserted into aperture 4a. Holding arm 8 is inserted into aperture 4b, and soldering tine 9 extends downward from the bottom to the outside of insulated housing 2. Tine 9 is inserted into a hole in a circuit board (not shown) and connected by soldering, for example. The FFC "C" used in conjunction with FFC connector 1 has multiple, flat, parallel leads W which are insulated from each other and are coated and adhered to a plastic base. Additionally, slit S, which has a predetermined width, is formed in the end of cable C to determine the insertion orientation into the cable insertion groove 3. Slit S aligns with positioning key 5 of the cable insertion groove 3 and cable C is then pushed into groove 3. Through this pushing, each exposed lead W at the end of FFC C makes electrical contact with contact point 7a formed near the tip of each contact arm 7. In such prior FFC connectors, it is difficult to arrange a large enough contact pressure for each contact between FFC C and FFC connector 1 due to the FFC's frictional properties. if the contact pressure is fairly large, the insertion force increases and it becomes difficult to insert FFC C into cable insertion groove 3. On the other hand, if the contact pressure is too small, the electrical contact becomes insecure and there is concern that FFC C could come out of FFC connector 1 under a comparatively small separation force. Therefore, an FFC connector is required which has a low insertion force along with an adequate extraction force so that FFC C is not extracted from FFC connector 1 even if a relatively large separation force is applied. Therefore, in Japanese Utility Application 3-358045, for such an FFC connector this applicant previously proposed pushing in and securing a separate key plug, formed of an elastic plastic member, into a slot in the insulated housing instead of a bar unitarily molded at both ends to the insulated housing and crossing the cable insertion groove, so that the key plug engages with a non-linear slit formed in the end of the FFC. They key plug and FFC slit do not greatly increase the insertion force, and engagement of the slit's stepped unit increases the extraction force when it is desired to extract the FFC. However, using a separate key plug in the insulated housing has the disadvantage of increasing the number of parts and the number of assembly processes, so that it results in a complicated design with high cost. The present invention consists in an electrical connector for a flat cable, comprising a connector housing having a plurality of spaced contact receiving sections, each of which comprises first and second apertures along a first surface of the connector housing and contact members having resilient contact arms disposed in the first apertures and holder projections disposed in the second apertures, a contact insertion aperture along an opposite surface of the connector housing, and an elongated cable insertion aperture along the first surface and transecting each of the first apertures, whereby upon insertion of a flat cable into the cable insertion aperture, the leads of the cable engage the contact arms for electrical continuity therewith, characterised in that a groove is formed between a pair of the contact receiving sections, said groove including a resilient beam projecting from a first wall thereof and having a longitudinal axis which extends across the cable insertion groove, said beam defining a gap between an end surface thereof and a second, opposite wall of said groove. Hence, the instant invention provides an FFC connector which has a single-beam-shaped key member that may be molded in one piece with the insulated housing in a direction which crosses the cable insertion aperture of the insulated housing. Additionally, the key member may be formed with a tapered engaging side, for example, and is engageable with a non-linear side wall or stepped part or an FFC slit and thereby increases the FFC extraction force. In one embodiment of the invention, the FFC slit is formed non-symmetrically and one end of the key member is secured in the side wall of the cable insertion groove and the free end is formed in a single beam shape projecting inside the cable insertion groove. In another embodiment, the FFC slit is formed almost symmetrically and one end of the key member is formed into a single-beam shape secured in the bottom of the cable insertion groove. This invention enables the provision of a flat-cable connector that can be easily miniaturized and densely packed, that has superior operability, and the facilitates continuity testing. In order that the invention may be more readily understood, reference will now be made to the accompanying drawings, in which:- Figure 1 is a top view of a flat-cable connector, Figure 2 is a front view of the connector shown in Figure 1, Figure 3 is a cross-sectional view of the flat-cable connector along line 3-3 in Figure 1 and illustrates an optional feature that may be embodied in a connector according to the invention, Figure 4 is a cross-sectional view showing the engagement of the electrical contact of Figure 3 and the insulated housing, Figure 5 is a perspective view showing an FFC connector according to one embodiment of the instant invention and an FFC used therewith, Figure 6 is a top view of the connector shown in Figure 5, Figure 7 is a front view showing one example of a contact used in the FFC connector in Figure 5, Figure 8 is a view showing an FFC connector according to another embodiment of the instant invention and an FFC used therewith, Figure 9 is a view showing a conventional FFC connector, Figure 10 is a cross-sectional view of the connector of Figure 9 taken along line B-B of Figure 9, and Figure 11 shows a conventional FFC for use with the connector of Figure 9. Figures 1 to 4 are described herein for the purposes of more adequately explaining the invention and a feature that may be embodied in a connector according to the invention, although these figures, themselves, do not illustrate the essential elements of the invention. Referring to Figures 1 to 4, the connector illustrated has ten contacts, but this is merely an example. Of course, the number of contacts can be increased or decreased, as desired, depending on need or usage. Flat-cable connector 10 (hereafter referred to as FFC connector 10) is generally composed of multiple contacts 40 and insulated housing 20, which is long, slender, nearly rectangular, and made of plastic. Insulated housing 20 has multiple (ten in this specific embodiment) pairs of first and second apertures 23,24 penetrating from bottom 21 to top 22 and longitudinally formed at fixed intervals (for example, at a pitch of 1.25mm). Also, a narrow, long cable insertion aperture 25, which connects with first apertures 23, is formed through insulated housing top 22 toward the bottom 21. A pair of round, column-shaped projections 26a, 26b for determining position are formed near both ends of the bottom 21. Furthermore, notches 29 are disposed near the bottom of both sides 27 and 29 of insulated housing 20 and are formed so as to reduce the side wall thickness of the insulated housing, for reasons to be described later. As shown best in Figure 1, a taper 30 is formed in the top of cable insertion aperture 25 which creates a guide for the FFC end and makes the insertion operation easy. Additionally, as shown best in Figure 3, first aperture 23 and second aperture 24 correspond to the thickness of contacts (to be described below) and are formed to penetrate from insulated housing bottom 21 to top 22. Figure 3 is a cross-section along line 3-3 in Figure 1. Each contact 40 is made up of a base 41 which has barbs 42 and 43 formed at both ends; a contact unit 44 and a holder 46, which are beam-shaped and extend upward from near both ends of the top of the base 41; and a solder tine 48, which extends downward from one end of the bottom of the base. Under normal conditions, contact unit 44 slants to the left side in the diagram and its tip has hook-shaped contact point 45, which projects inside cable insertion aperture 25. Holder 46 is formed with a long aperture 47 running almost its entire length in the longitudinal direction. Furthermore, as shown in Figure 4, contact holder 46 can be bent in almost a U-shape along its entire length so that near its base 41 and tip 46a it engages one of the inside walls 24a of the aperture 24; and its central bend 46b engages the other inside wall 24b. By structuring contact 40 in this way, contact 40 is securely fixed in second aperture 24 by barbs 42 and 43 and by holder 46. There is a concern that insulated housing side walls 27 and 28 will bulge outwardly because of barbs 42 and 43 pushing of the wall material at both ends of contact base 41. But, as described above, notches 29 are formed on the outer surface of side walls 27 and 28, so the outer surfaces of side walls 27 and 28 do not protrude outwardly. Additionally, making this part of insulated housing 20 thinner or notched ensures a good insertion operation for contact 20 and ensures a good friction engagement with barbs 42 and 43. In this specific embodiment of the invention, the dimensions of the insulated housing 20 are a height of about 6.0 mm and a depth (or thickness) of 4.0 cm. Width depends on contact pitch and number of contacts. Furthermore, Figure 3 shows the end of FFC 50 being inserted into cable insertion aperture 25. The contact point 45 of beam-shaped contact unit 44 has an inclined hook shape on its upper surface, so when FFC 50 is inserted, contact unit 44 bends outward (to the right) and it is possible to insert the FFC's tip. However, once it has been inserted, FFC 50 is held by the hook structure of contact point 45, and the contact point 45 and the FFC's lead (not shown) are maintained in an electrically and mechanically engaged state unless a relatively large tension is applied. Furthermore, first aperture 23 and second aperture 24 both penetrate to insulated housing top 22, so that the insertion status of contact 40 can easily be confirmed from above. Additionally, one can insert a probe that has a pointed electrode from insulated housing top 22 into second aperture 24 for a continuity check. Because of this continuity check function, the upper part of second aperture 24 might be made a little larger than the lower part to improve the probe insertion operability. The FFC connector described in detail above, is not limited to the specific construction described. For example, contact 40 might have an SMT (surface mounting) tine instead of solder tine 48. Additionally, adjacent contact tines might be alternately arranged on opposite sides of the insulated housing in a staggered pattern. Each contact holder 46 could extend through second aperture 24 to near insulated housing top 22 or could partially project through the top. Furthermore, if necessary, a slit could be formed in position-determining projection 26, as disclosed in Japanese Utility Application 3-100367, and a separate flat elastic metal holder fitting could be incorporated into it. Or instead of position-determining projection 26, separate elastic metal securing units could be pushed into and secured in apertures near both ends of the insulating housing, as is disclosed in Japanese Utility Model 1-42645. In a first embodiment according to the invention and illustrated in Figures 5 and 6, connector 10 has a long, thin, nearly rectangular insulated housing 20'. Long thin cable insertion groove 22' is formed in top 21' of insulated housing 20' and extends along the longitudinal direction and toward the bottom. A taper is formed in the top of cable insertion groove 22'. Multiple contact-receiving apertures 23'-24' are formed in pairs along and on both sides of cable insertion groove 22' and they penetrate from top 21' to the bottom. Contact arms and holder arms (described below) are pressed into and held in these contact-receiving apertures 23'-24' from the bottom. As shown in the drawing, aperture 23' connects to cable insertion groove 22' and is arranged so that the contact point on the end of the contact arm projects into cable insertion groove 22'. The number and pitch of adjacent contact-receiving apertures 23'-24' is determined by the number and pitch of the leads in the FFC used. Additionally, notch or groove 25' is formed in insulated housing 20' to cross, or transect, and connect with cable insertion groove 22' at a position off-center in the longitudinal direction of cable insertion groove 22'. For example, as shown in Figure 6, it is to the right. Single-beam-shaped key member 27' is formed of the same material as insulated housing 20' and is preferably unitarily molded. It is secured to one side wall 26' of notch or groove 25', and points toward the opposite side wall, and is positioned a little below top 21' of insulated housing 20'. Taper 28' is formed on the top and both sides of key member 27', and engaging unit 29' is formed on its bottom to engage with the FFC slot side walls to be described later. If key member 27' is formed in insulated housing 20' in this manner, key member 27' has cantilever flexibility in a direction along cable insertion groove 22'. The end of FFC 30', which is inserted and used in FFC connector 10', exposes multiple flat leads 31a, 31b as shown in the partially magnified perspective view in Figure 5. Additionally, slit 32, which is not laterally symmetrical, is formed between leads 31a and 31b. That is, one side wall 33 of the slit 32 is almost linear, but the other side wall 34 is a non-linear and has a stepped part 35 which has a taper and is formed near the end. Furthermore, taper 36 is formed at both sides of the slit entrance. Figure 7 shows one side of contact 40', which is inserted and held in contact-receiving apertures 23'-34' in insulated housing 20' of Figure 1 or 5. As shown in Figure 7, the contacts are formed by cutting out an elastic metal sheet that has a prescribed thickness, and alternately positioning and mounting one end of tall contact 40a' and short contact 40b' on carrier strip 41'. For simplicity, Figure 7 shows only one pair. Both contacts 40a' and 40b' are equipped with contact arm 43', which extends upward from the upper right side of base 42' and has contact point 44' at the end, and holding arm 45', which extends upward from the left side and has long thin aperture 46' in its center. Additionally, contacts 40a' and 40b' have a pair of solder tines 47 and 48 extending downward from the left and right sides of base 42'; if necessary, either of them can be eliminated for a staggered arrangement. As described above, the contacts 40a' and 40b' are pressed in from the bottom of insulated housing 20' so that contact arm 43' and holding arm 45' thereby enter contact-receiving apertures 23'-24'. Alternately pushing tall or short contacts 40a' and 40b' into adjacent positions in contact-receiving apertures 23'-24' alternately offsets the distance top 21' to contact point 44', and in this way the insertion force for FFC 30'is reduced even more. An explanation of the operation of inserting the end of FFC 30' into FFC connector 10' designed as described above is now in order. First, when inserting the end of FFC 30' into cable insertion groove 22' in insulated housing 20', slit 32 is positioned so that it matches the key member 27' of cable insertion groove 22'. Next, FFC 30' is pushed into cable insertion groove 22' a little, and the slit 32 of FFC 30' has a taper 36 which makes contact with taper 28' on key member 27'. When pushed in more, key member 27' is bent or resiliently deflected to the left by the stepped part 35 on right side wall 34 of the slit 32. Next, the FFC 30' has leads 31a, 31b which make contact with point 44' on tall contact 40a'. When it advances farther, the contact point 44' makes contact with leads 31a, 31b. Finally, the neck of slit 32 passes key member 27, which was bent or deflected to the left, then returns to the normal, undeflected position, and its engaging unit 29 engages with stepped part 35, which is slanted on slit side wall 34. Through this engagement, FFC 20' is securely held in cable insertion groove 22' even if a relatively large tension operates on FFC 30'. When releasing the engagement of FFC 30' and FFC connector 20', a sufficiently large tension is applied to FFC 30'. When doing so, slit stepped part 35 bends or resiliently deflects key member 29' to the left, and in the reverse of what was described above, contact point 44' and FFC 30' leads 31a, 31b separate from the contact and FFC 30' is extracted from FFC connector 10'. At this time, key member 27' reverts to its original position due to its innate elasticity or resiliency. The extraction force here depends on the shape of slit 32 and in particular on the angle of inclination of stepped part 35 and the shape of the key member engaging unit 29'. Another embodiment of this invention is here explained with reference to Figure 8. Figure 8 is a perspective view of the key parts of the connector insulated housing 60. Figure 8 includes a perspective view of the key parts of FFC 70, which is used therewith. This embodiment of FFC connector 50 is suitable when both side walls 73 and 74 of FFC slit 72 are non-linear, i.e., when the entrance narrows and is nearly symmetrical or is offset. The insulated housing's key member 67 has a single-beam shape secured at the bottom so it crosses cable insertion groove 62. Also, a taper is formed on the top of key member 67, to serve as a guide for FFC slit 72. Additionally, engaging unit 69, which projects to the side and has a slanted engaging surface, is formed at the bottom of both sides of key member 67. Key member 67 and FFC slit 72 have a relative flexibility, even in FFC connector 50, and the engaged and inserted end of FFC 70 is firmly held in cable insertion groove 62. Of course, if sufficient tension is applied to FFC 70, FFC 70 is extracted from cable insertion groove 62. The FFC connector of the invention has a slit which has a nonlinear side wall that not only orients the FFC end but also increases the extraction force, and forms and arranges a single-beam-shaped key member which engages with the inside the cable insertion groove. Such a key member is unitarily formed with the insulated housing, so it can be manufactured at low cost. Additionally, the key member itself can be displaced in the longitudinal direction of the cable insertion groove so, even if the FFC's slit is non-symmetrical or slightly out of position causing a discrepancy in the friction engaging force, the FFC does not buckle and can be inserted smoothly. Moreover, the extraction force can be increased without greatly increasing the insertion force, so a secure connection can be maintained even when used in portable electronic devices which experience vibration and shock.

Claims: An electrical connector (10',50) for a flat cable (30',70), comprising a connector housing (20',60) having a plurality of spaced contact receiving sections, each of which comprises first and second apertures (23',24';63,64) along a first surface (21',61) of the connector housing and contact members (40a',40b') having resilient contact arms (43') disposed in the first apertures (23',63) and holder projections (45') disposed in the second apertures (24',64), a contact insertion aperture along an opposite surface of the connector housing, and an elongated cable insertion aperture (22',62) along the first surface and transecting each of the first apertures (23',63), whereby upon insertion of a flat cable into the cable insertion aperture, the leads of the cable engage the contact arms (43') for electrical continuity therewith, characterised in that a groove (25') is formed between a pair of the contact receiving sections, said groove including a resilient beam (27',67) projecting from a first wall (26') thereof and having a longitudinal axis which extends across the cable insertion aperture (22',62), said beam defining a gap between an end surface thereof and a second, opposite wall of said groove. The electrical connector of claim 1, wherein the resilient beam (27',67) is deflectable in a direction along the cable insertion aperture (22',62) in response to engagement with the flat cable (30',70). The electrical connector of claim 1 or 2, wherein the holder projection (45') comprises an arcuate bend across a transverse section thereof. The electrical connector of claim 3, wherein said arcuate bend section has a first end which engages a wall of the second aperture (24',64) and an intermediate portion which engages an opposite wall of said second aperture. The electrical connector of claim 1, 2 or 3, wherein said opposite surface of the connector housing includes at least one positioning projection formed thereon. The electrical connector of any preceding claim, wherein at least one notch is formed on an outer surface of the connector housing and is located outwardly of at least one barb formed on at least one of the contact members (40a',40b'). The electrical connector of claim 6, wherein the contact arms (43') are of unequal lengths and are alternately spaced in the connector housing according to their lengths, and wherein a short contact arm is disposed between two relatively longer contact arms.

Inventors: IMAI AKIRA, IMAI, AKIRA
Applicants: WHITAKER CORP, THE WHITAKER CORPORATION
Application year: 1993
Main classification: H01R9
IPC codes: H01R12, H01R13