Patent ID: 12191587

DETAILED DESCRIPTION OF THE EMBODIMENTS

Exemplary embodiments of the present disclosure will be described hereinafter in detail with reference to the attached drawings, wherein like reference numerals refer to like elements. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure will convey the concept of the disclosure to those skilled in the art. In addition, in the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it is apparent that one or more embodiments may also be implemented without these specific details.

Embodiments of the present disclosure include conductive connector shields or shield housings configured for use with FFCs and/or FPCs. The shield housings include integrated contact elements for establishing reliable electrical contact with shielding conductors, such as shielding foil layers and/or ground or drain conductors, embedded within the insulation material of the cable.

FIG.1is a cross-sectional view of an exemplary FFC10useful for describing shields according to embodiments of the present disclosure. The FFC10includes a plurality of conductors or conductive traces, for example, a pair of central signal conductors12, also referred to herein as first conductors, bordered on either side by second conductors14, such as ground and/or drain conductors. The representative FFC10further includes upper and lower shielding layers16, for example, metallic foil shielding. The conductors12,14and shielding layers16are embedded within an insulation material18, such as a polymer material. As set forth above, when terminating and connectorizing the signal conductors12, it is often desirable to shield the finished connector assembly. According to embodiments of the present disclosure, this achieved via a metallic shield housing or shell that surrounds the terminated ends of the signal conductors12, and electrically contacts the shielding layers16and/or the ground or drain conductors14of the FFC10.

Referring now toFIG.2, advantageously, FFCs and FPCs may be manufactured with a predetermined end profile, eliminating the need for further processing steps prior to connectorization to expose the signal and/or shielding conductors thereof (e.g., stripping, as required for round-wire termination). As illustrated, a free end20of the exemplary FFC10according to an embodiment of the present disclosure has been manufactured with shortened second conductors14and shielding layers16relative to the signal conductors12in an axial direction of the cable. Further, top surfaces of a portion of each of the second conductors14are left exposed. As will be set forth in detail herein, the exemplary preconfigured end profile or free end20of the FFC10enables shield housings according to embodiments of the present disclosure to more easily and reliably establish electrical connections with the embedded shielding layers16and conductors14of the cable.

FIG.3generally shows a complete FFC assembly30comprising a shield or shield housing31including an upper housing or shell32joined with a lower housing or shell34. The upper and lower housings32,34may comprise sheet metal components formed from stamping, folding and other similar operations. The shield housing31defines a connector space36at a first end thereof in which the signal conductors12of the FFC10are terminated and/or connectorized, and a cable space38at a second end thereof at least partially receiving the free end of the FFC, including the shielding layers16and ground conductors14thereof. As shown, the cable space38has a width greater than that of the connector space36, and a height less than that of the connector space for receiving the correspondingly-sized FFC10. Likewise, the connector space36narrows relative to the cable space38and increases in height in order to receive the terminals and/or a connector body fitted to the signal conductors12.

Referring now toFIGS.4-6, according to an embodiment of the present disclosure, the lower housing or shell34defines a plurality of integral contact elements35in the form of sharpened tines or crimping features. More specifically, the contact elements35may define piercing, crimpable elements, or insulation-displacement contacts (IDCs), or insulation-piercing contacts (IPCs), for establishing electrical connections through the insulation material18of the FFC10. In the exemplary embodiment, the contact elements35may be arranged in two pairs of rows, with each row defining a plurality of tines, and each pair of rows arranged offset from an axial center of lower housing shell34. Referring toFIGS.5and6, portions of the upper housing32and the lower housing34have been removed to reveal the resulting electrical connections between the contact elements35and the conductors14and lower shielding layer16within the cable space38(FIG.5), as well as the termination of the signal conductors12within the connector space36(FIG.6).

As illustrated inFIG.5, the contact elements35are configured to penetrate the lower or bottom portion of the insulation18, and contact or penetrate both the lower shielding layer16as well as each of the conductors14of the exemplary FFC10. More specifically, the contact elements35of a given pair of rows penetrates a respective one of the conductors14on each side of the signal conductors12. A central space defined between the laterally-offset contact elements35permits the passage of the signal conductors12and associated insulation material18therebetween. In this way, the signal conductors12extend uninterrupted into the connector space36of the housing31,34for termination, as shown inFIG.6. In a subsequent processing step, the contact elements35may be crimped or folded into compressive contact with the insulation material18of the FFC10.

Referring particularly toFIGS.3and5, the upper housing32may be fixed to the lower housing34via a locking assembly28. The locking assembly28comprises, by way of example, complementary snap-fit latching features, including latching protrusions or latches37and corresponding latch openings or catches39. The contact elements35may penetrate the FFC10under the compressive force used to join and lock the upper and lower housings32,34, with the mated locking assembly28ensuring that electrical contact between the contact elements35, and the conductors14and shielding layers16is reliably maintained.

Referring now toFIGS.7and8, a shield assembly70according to another embodiment of the present disclosure is provided. As shown inFIG.7, in which a lower housing74of the shield has been removed, the FFC10of the assembly70may be manufactured with a different free end profile compared to that set forth above with respect to the preceding embodiment. More specifically, the FFC10includes windows or openings76formed therein proximate a free end for exposing the upper shielding layer16. While the FFC10is shown with the openings76formed only through a top side of the insulation material18, in addition to or in place of these openings, windows or openings may also be formed in a bottom side of the FFC for exposing the lower shielding layer16, without departing from the scope of the present disclosure.

An upper housing or shell72of the assembly70includes a first top section72′ oriented generally parallel with the FFC10for defining the above-described connector space of the housing, and a second top section72″ extending or declining obliquely downward from the first top section and in a direction toward the FFC for defining the cable space. The second top section72″ defines one or more contact elements75extending therefrom. The contact elements75define lances or elongated projections positioned to engage the preformed openings76in the insulating material18for establishing conductive contact with the shielding layer16of the FFC10. In some embodiments, the contact elements75may be configured to merely contact the shielding layer16. In other embodiments, the contact elements75may be sized and shaped to penetrate the shielding layer16, and may establish contact with the underlying conductors14. In still other embodiments, the preformed openings76in the FFC10may not be present, and the upper housing72may establish electrical contact with the foil shield16via the contact elements75penetrating the insulation material18under a compressive force, such as that generated when the upper housing72is connected to the lower housing74, as shown inFIG.8.

Referring particularly toFIG.8, the lower housing74comprises sidewalls74′ each having a complementary tapered or inclined profile matching that of the second top section72″. The sidewalls74′ further define a slot74″ formed therethrough and sized to accept the free end of the FFC10. The lower housing74is attached to the upper housing72via a locking assembly78defining snap-fit and/or latching connections, each including a latch77and recess79similar to those as described above with respect toFIGS.3-6. The locking assemblies78are located on a lower end of the second top section72″ proximate to the contact elements75for maintaining a tension force on the upper housing72, ensuring reliable electrical contact between the contact elements75and the shielding layer16and/or the conductors14of the FFC10. As shown inFIG.7, a second recess79may be formed in the first top section72′ of the upper housing72for receiving another latch of the lower housing74. In this way, shield housings according to embodiments of the present disclosure may include multiple pairs of snap-fit connections along their length in the axial direction of the FFC10.

Referring now toFIGS.9and10, a shield assembly90according to another embodiment of the present disclosure is shown. The exemplary FFC10of the assembly90defines a slotted opening96formed across an entire width of the insulation material18for exposing the upper shielding layer16. An upper housing92of the shield includes first and second top sections92′,92″, similar to those described above with respect toFIGS.7and8. The second top section92″ defines contact elements95in the form of two substantially L-shaped cantilevered arms or beams extending therefrom. More specifically, each contact element95extends downwardly from the second top section92″ of the upper housing92in the illustrated orientation, and bends or turns inwardly, defining a free end extending generally parallel with the shielding layer16. In this way, free ends of the contact elements95extend toward one another and in the direction of an axial center of the FFC10. With a lower housing fitted to the upper housing92(seeFIG.8), the contact elements95provide a normal force acting on the upper shielding layer16for establishing electrical contact. The elasticity provided by the cantilevered nature of the contact elements95ensures the contact force on the shielding layer16remains consistent.

Still referring toFIGS.9and10, as the second top section92″ of the upper housing92is inclined with respect to the first top section92′ as it transitions between the cable space and the connector space, the contact elements95extend from the second top section92″ in an oblique orientation such that they are oriented normal to a horizontal plane defined by the shielding layer16. Further, the contact elements95extend from the second top section92″ at a point directly adjacent to a latch or protrusion97of a locking assembly of the housing. In this way, bending is reduced on the upper housing92after a lower housing is fitted and the contact elements95are compressed onto or into the shielding layer16.

A shield assembly100shown inFIG.11includes features similar to those described above with respect toFIGS.9and10, with only the differences described further herein. In distinction to the embodiment ofFIGS.9and10, a declining second top section102″ of an upper housing102of the assembly100defines two pairs of beam-shaped contact elements95,95′ extending into two slotted openings96formed in the insulation material18of the FFC10. The use of two pairs of contact elements95,95′ both increases the contact area between the shield housing and the exposed shielding layer16, as well as more evenly distributes compression forces acting thereon. The distribution of forces is also improved by arranging each pair of contact elements95,95′ on opposite sides of the latch or protrusions97of the upper housing102.

Similarly, the embodiment ofFIG.12includes an upper housing112including a second top section112″ defining a first pair of contact elements95or beams arranged on a first side of the latch or protrusion97, and a substantially U-shaped rear contact element105. The rear contact105is arranged on a second side of the latch or protrusion97and defines a curled free end extending generally in an axial direction of the FFC10. Like the embodiment ofFIG.11, in addition to increasing the surface area of electrical contact between the shield and the cable conductors, the introduction of an additional point of contact on the shielding layer16by the rear contact element105increases stability by more evenly distributing compressive forces, as well as reducing the resulting bending forces acting on the shield.

FIGS.13-16illustrate another shield assembly130including upper and lower shield housings132,134, each defining a respective flat or linear end section132′,134′ extending parallel to the FFC10. More specifically, the FFC10defines recessed ends136formed in the insulation material18for exposing respective top and bottom planar surfaces of the upper and lower shielding layers16, as shown inFIGS.13and16. Interior or bottom planar surfaces of the linear end sections132′,134′ define contact elements115in the form of foil picks, as shown inFIGS.14-16. In one embodiment, the contact elements115are arranged in a pair of adjacent rows, with each row having contact elements defining free ends curved in a direction opposing the curved free ends of the contact elements of the adjacent row. Two such arrangements are formed on lateral sides of both the upper and lower housings132,134, with the signal conductors12of the FFC10extending freely therebetween. A locking assembly138, including latches137and associated recesses139, is formed on respective inclined sections132″,134″ of the upper and lower housings132,134which extend obliquely from the linear end sections132′,134′ and toward a connector space of the assembled housing. Like the embodiment ofFIG.8, the lower housing134further defines a slot140formed therethrough (i.e., through each sidewall thereof) which is sized to receive a free end of the FFC10therein in the illustrated manner.

The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range.

Also, the indefinite articles “a” and “an” preceding an element or component of the invention are intended to be nonrestrictive regarding the number of instances, that is, occurrences of the element or component. Therefore “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.