Abstract:
A method of securing a flat cable to a circuit board including the steps of providing a flat cable with a plurality of round conductors therein and a circuit board having a plurality of solder pads. The method also includes stripping an end of the flat cable to expose the round conductors therein, placing the round conductors onto the solder pads, and soldering the round conductors to the solder pads.

Description:
RELATED APPLICATION  
       [0001]     This application is a divisional application of copending U.S. patent application Ser. No. 10/646,786, filed Aug. 25, 2003 and entitled Clockspring Flat Cable Termination, the subject matter of which is incorporated by reference. 
     
    
     FIELD OF INVENTION  
       [0002]     The present invention relates to clocksprings used in automobiles, and in particular, the termination and the method of terminating a flat electrical cable having round conductors therein by soldering to a circuit board in a clockspring.  
       BACKGROUND OF THE INVENTION  
       [0003]     A majority of automobiles today utilize airbag crash systems. An airbag is typically located on the steering wheel facing the driver and must be in continuous electrical connection with sensors in the car body. The sensors provide an electrical signal to the airbag crash assembly which instantly inflates the airbag in the event of a crash. Clocksprings are found in virtually every vehicle to electrically connect rotating devices in the steering column to stationary components in other parts of the vehicle.  
         [0004]     To facilitate the rotation of the clockspring, the electrical cable located within the housing of the clockspring is a flat cable which is wound around a central hub of the clockspring. The flat cable is terminated at a circuit board on the clockspring, for eventual connection to the airbag or other electrical device within the car. These connections are oftentimes made by welding the conductors in the flat cable to metal leads on the insert molded circuit board.  
         [0005]      FIGS. 1   a - 1   d  show a current clockspring termination structure.  FIG. 1   a  shows a bottom view of the exterior of a clockspring housing  10 . The housing  10  includes two connection modules  12  and  14 , each module having contacts  18  therein. The contacts  18  can be better seen in  FIGS. 1   b - 1   d .  FIG. 1   b  shows a insert molded circuit board  16  which holds a total often ( 10 ) contacts  18  for both connection modules  12  and  14 . The contacts  18  are connected to metal conductors  20  molded into the circuit board  16 , which eventually form metal leads  22 .  FIGS. 1   c  and  1   d  show a top and perspective view, respectively, of a flat cable  24  with ten (10) flat conductors  26  welded to the metal leads  22 , with each flat conductor  26  welded to a single metal lead  22 .  
         [0006]     The flat cable  24  is generally formed by sandwiching the flat conductors  26  between two insulating layers of plastic or similar material. The insulating layers in  FIGS. 1   c  and  1   b  are transparent so that the flat conductors  26  can be seen. The insulating layers have an adhesive bonding agent on their interior sides which bond to each other and to the flat conductors  26 . The ends of the flat cable  24  are stripped to expose the flat conductors  26  therein, which are then welded to the metal leads  22 .  
         [0007]     The welding structure of the prior art suffers from the disadvantage that it requires the metal leads to be spaced relatively far apart, resulting in larger clocksprings. The metal leads  22  are formed by a stamping process which requires that they be spaced a distance generally equal to the thickness of the metal leads  22  (in  FIG. 1   b , the thickness of the metal leads  22  is the height of the metal lead  22  going into and out of the page). This is necessary to prevent the metal leads  22  from deforming or jamming the stamping die during the stamping process.  
         [0008]     A possible solution to this problem is to solder the flat conductors  26  directly to the insert molded circuit board  16 . Soldering would remove the need for the metal leads  22 , which would be replaced by solder pads that could be laid onto the insert molded circuit board  16  without the spacing demands of the metal leads  22 . However, soldering flat conductors is not practiced because of the shortcoming of soldering a flat conductor to a flat surface. The interface between a flat conductor and a solder surface are not conducive to solder joints and provide a weak bond between the two surfaces.  
         [0009]     Because of this drawback, most soldering is performed using round conductors. However, round conductors have not been used in flat cables because of the difficulty in removing the adhesive residue around the conductors. The presence of adhesive residue in solder joints weakens the joint, compromising its reliability and quality. Flat cables with flat conductors are typically stripped at the ends by grinding the insulating layers and adhesive off the flat conductors, which is effective in removing the majority of the adhesive residue. However, the grinding process cannot be used with round conductors because of the conductor&#39;s curvature. There is no way of accessing the adhesive at the round conductor&#39;s edges without grinding away portions of the conductor itself. Therefore, flat cables having round conductors have not been previously soldered to insert molded circuit boards.  
         [0010]     More recently, a method of manufacturing flat cables without the use of adhesives has been disclosed in U.S. Pat. No. 6,026,563, issued to Tom Schilson (hereinafter referred to as “the &#39;563 patent”) and assigned to Methode Electronics, Inc. of Chicago, Ill. The &#39;563 patent is hereby incorporated in its entirety by reference. The &#39;563 patent discloses a method of ultrasonically welding polyester layers around the conductors of a flat cable without using adhesives.  
         [0011]     In view of the foregoing, it would be advantageous to provide a flat cable manufactured without the use of adhesives and having round conductors that may be soldered to an insert molded circuit board. It would be a further advantage to provide a high density flat cable having conductors that are spaced closely together and that are soldered to the solder pads of the insert molded circuit board to provide a flat cable with greater signal capacity.  
       SUMMARY OF THE INVENTION  
       [0012]     The present invention is directed towards a solder joint between a flat cable having round conductors and the solder pads of a circuit board in an automotive clockspring. The flat cable is formed by a top and bottom layer of insulating material which cover the round conductors. The insulating layers are bonded to one another using a sonic welding process, which allows the flat cable to be manufactured without the use of adhesives. The ends of the flat cable are stripped to expose the ends of the round conductors, which are then soldered to the solder pads on the insert molded circuit board using a hot bar soldering process.  
         [0013]     Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:  
         [0015]      FIG. 1 a  shows a bottom view of the exterior of a prior art clockspring housing;  
         [0016]      FIG. 1   b  shows a circuit board used in a prior art clockspring;  
         [0017]      FIG. 1   c  and  1   d  show a flat cable welded to the circuit board of the prior art clockispring;  
         [0018]      FIGS. 2   a  and  2   b  show a bottom view of the clockspring housing of the present invention, with and without a cable cover, respectively;  
         [0019]      FIG. 2   c  shows a connection module located on the clockspring housing of the present invention;  
         [0020]      FIGS. 3   a - 3   c  show a flat cable soldered to a circuit board of the clockspring of the present invention; and  
         [0021]      FIG. 4  shows round conductors placed onto solder pads of a circuit board of the present invention;  
         [0022]      FIG. 4   a  shows an end view of the round conductors along line  4 - 4  of  FIG. 4 ; and  
         [0023]      FIG. 5  shows the round conductors soldered to the solder pads of the circuit board of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     Referring now to the several drawing figures in which identical elements are numbered identically throughout, a description of the preferred embodiment of the present invention will be provided.  
         [0025]      FIGS. 2   a - 2   c  shows a bottom view of the clockspring housing  100  of the present invention having a connection module  102  with sixteen (16) contacts  106  therein.  FIG. 2   a  shows the housing  100  a cable cover  103  while  FIG. 2   b  shows the cable cover  103  removed and a high density flat cable  112  lying therein. An end of the flat cable  112  is soldered to an insert molded circuit board  104  in the connection module  102 , as explained later in greater detail.  FIG. 2   c  shows an exploded view of the connection module  102  of  FIG. 2   b.    
         [0026]     The circuit board  104  is shown in greater detail in  FIGS. 3-5 . The circuit board  104  has two rows of contacts  106  which connect to metal conductors  108  and end in solder pads  110 . The solder pads  110  allow for much closer spacing as compared to the metal leads  22  of the prior art because they do not need to meet the spacing demands of the stamping process for the metal lead  22 . More specifically, because the solder pads  110  can simply be laid onto the circuit board  104 , the spacing requirements for stamping metal leads  22  a distance equal to their thickness to prevent deformation, are not present in the present application. The closer spacing of the solder pads  110  allow a flat cable to have more conductors, i.e., have a higher conductor density, than a flat cable produced using the welding process of the prior art. It should be noted that although  FIGS. 3-5  show the contacts  106  of the circuit board  104  arranged in a double row of eight (8) contacts, the contacts  106  can be arranged in any pattern and remain within the scope of the present invention.  
         [0027]      FIGS. 4 and 5  show the sixteen (16) conductor high density flat cable  112  having round conductors  114  soldered to the circuit board at the solder pads  110 , with each conductor  114  being soldered to a single solder pad  110 . The high density flat cable  112  includes a top and bottom insulating layer  113  made of plastic or similar material that cover the round conductors  114 .  FIGS. 3   b  and  3   c  show transparent insulating layers  113  so that the conductors  114  inside the flat cable  112  can be seen. The insulating layers  113  are bonded to each other using any non-adhesive means, an example of which is disclosed in U.S. Pat. No. 6,026,563 to Schilson, which is directed towards a method of sonically welding insulating layers around the conductors of a flat cable. The Schilson reference is hereby incorporated by reference in its entirety.  
         [0028]     The conductors  114  of the high density cable  112  are round which facilitate the soldering of the conductor  114  to the solder pad  110 .  FIG. 4   a  shows an end view of the round conductor  114  along line  4 - 4  of  FIG. 4 . The round conductor  114  provide a groove  120  at the intersection of the round conductor  114  and the solder pad  110 , which promotes wicking of solder material to fill the groove and form a stable solder joint.  
         [0029]     An additional benefit of using round conductors is that the width of the solder pads  110  only needs to be as wide as the thickness of the round conductor  114 , or only slightly wider. This is because of the grooves  120  at the intersection of the round conductor  114  and solder pad  110  provide the necessary space for the soldering material to bond the conductor  114  and the solder pad  110 . In contrast, soldering a flat conductor would require larger solder pads  110 , because considerable space, typically ½ the width of the flat conductor, is necessary adjacent the contact point between the flat conductor and solder pad for the solder material to accumulate.  
         [0030]     Therefore, flat cables having round conductors that are soldered to the solder pads of a circuit board allow for a higher conductor density, increasing the amount of signal the flat cable is capable of carrying.  
         [0031]     The soldering process used in the present invention may use any known soldering method. However, in the preferred embodiment, a hot bar soldering process is used. The hot bar soldering process uses a solder paste  111 , which is a layer of soldering material formed over the solder pads  110  that melts and joins the round conductors  114  to the solder pads  110  during the soldering process. The solder paste  111  is shown in  FIG. 4   a . The conductors  114  are placed on the solder paste  111 , after which a heat bar (not shown) is brought into close proximity to the solder paste  111 , melting the solder paste  111  so that it flows around the conductors  114 . The solder paste  111  is then allowed to cool and harden forming a stable electrical bond between the solder pads  110  and the conductors  114 .  
         [0032]      FIG. 5  shows the conductors  114  after being soldering to the solder pads  110 . A solder fastening layer  116  is formed over the conductors  114  and fills the grooves  120  to join the conductors  114  to the solder pads  110 .  
         [0033]     Although preferred embodiments are specifically illustrated and described herein as being used with a clockspring, it should be appreciated that the structure and methods disclosed above may be used in situations not involving a clockspring, and many modifications and variations of the present invention are possible in light of the above teachings, without departing from the spirit or scope of the invention.