Patent ID: 12249818

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

FIGS.1and2present an electrical assembly20including a housing30, a flat cable40, one or more electrical wires50(e.g., electrical wires50A-50D), one or more terminals60(e.g., terminals60A-60D), and one or more dividers70(e.g., dividers70A-70E). The housing30is configured for connection with the flat cable40, the electrical wires50, the terminals60, and/or the dividers70. A terminal60is configured for connection with the flat cable40and an electrical wire50. The dividers70are configured for connection with the housing30. The cable40includes one or more electrical conductors80(e.g., conductors80A-80D) that have exposed portions82(e.g., exposed portions82A-82D). In an assembled configuration, the cable40is disposed at least partially in the housing30, the wires50(e.g., conventional round wires) are disposed partially in the housing30, and the terminals60and the dividers70are disposed in the housing30.

FIG.1shows a first terminal60A connected to a first exposed conductor portion82A and a first wire50A such that the first exposed conductor portion82A is electrically connected to the first wire50A, a second terminal60B connected to a second exposed conductor portion82B and a second wire50B such that the second exposed conductor portion82B is electrically connected to the second wire50B, a third terminal60C connected to a third exposed conductor portion82C and a third wire50C such that the third exposed conductor portion82C is electrically connected to the third wire50C, and a fourth terminal60D connected to a fourth exposed conductor portion82D and a fourth wire50D such that the fourth exposed conductor portion82D is electrically connected to the fourth wire50D. In some example configurations, a first distance D1between the first terminal60A and the second terminal60B is different than a second distance D2between the second terminal60B and the third terminal60C (see, e.g.,FIG.3). The assembly20is shown including four wires50, terminals60, and exposed conductor portions82, however the assembly20may include more or less than four wires50, terminals60, and exposed conductor portions82.

FIG.3shows a first divider70A disposed adjacent the first terminal60A, a second divider70B disposed between the first terminal60A and the second terminal60B, a third divider70C disposed between the second terminal60B and the third terminal60C, a fourth divider70D disposed between the third terminal60C and a fourth terminal60D, and a fifth divider70E disposed adjacent the fourth terminal60D. In some instances, a divider70is configured to electrically isolate adjacent terminals60. The assembly20is shown including five dividers70, however the assembly20may include more or less than five dividers70.

FIGS.1and2illustrate a housing30including a first cover90(e.g., an upper housing cover) and a second cover92(e.g., a lower housing cover). The first cover90is configured for connection with the second cover92, the flat cable40, the electrical wires50, the terminals60, and/or the dividers70. The second cover92is configured for connection with the first cover90, the flat cable40, the electrical wires50, the terminals60, and/or the dividers70.

FIG.4illustrates a first cover90including a planar base100, a first attachment feature102A, a second attachment feature102B, a wall104, and/or a projection106. Without limitation, in some configurations, the first attachment feature102A and/or the second attachment feature102B may comprise a wall-like portion (e.g., a beam) that includes a portion (e.g., upper portion) configured to connect to a separate component. In some example configurations, the first attachment feature102A and the second attachment feature102B extend from a first side110A of the base100and/or are configured to connected with a second cover92′ of a second housing30′ (see, e.g.,FIG.12). The wall104and the projection106extend from a second side110B of the base100and/or the projection106is spaced apart from the wall104. In some implementations, the projection106includes a first part112that extends from the base110and a second part114that extends parallel to and spaced part from the base110. Referring now toFIG.6, in an assembled configuration, portions of the terminals60are disposed in a recess116disposed between the wall104and the first part112of the projection106.

FIG.5illustrates a second cover92including an inner channel120, a first outer channel122A, and a second outer channel122B. In some example configurations, the inner channel120is disposed between the first outer channel122A and the second outer channel122B. In an assembled configuration, the dividers70are partially disposed in the inner channel120(see, e.g.,FIG.14).

With continued reference toFIG.5, in some instances, the second cover92includes a first attachment structure130A disposed in the first outer channel122A and a second attachment structure130B disposed in the second outer channel122B. In some examples, the first attachment structure130A is configured to connect with a first attachment feature102A of a first cover90and the second attachment structure130B is configured to connection with a second attachment feature102B of the first cover90(see, e.g.,FIG.12).

With reference toFIG.1, a flat cable40includes an elongated body84having one or more electrical conductors80and/or an insulating material86that electrically insulates the conductors and/or the conductors80from each other and/or other components. The electrical conductors80include exposed portions82that are not completely covered by insulating material86and/or from which insulating material86has been removed. The one or more conductors80and exposed portions82may be disposed in parallel with each other and/or may be substantially aligned with a common plane. The one or more conductors80may, in some configurations, be integrally formed with the insulating material86. The conductor portions80may have varying sized widths.

FIG.7illustrates a divider70including an elongated first portion140and a second portion142extending from the first portion140. In some example configurations, the first portion140includes a length140L that is greater than a length142L of the second portion142. Referring now toFIG.6, in an assembled configuration, the second portion142is disposed in the inner channel120of the second cover90. For instance, a divider70is positively engaged with the inner channel120such that removal of the divider70from the second cover is restricted.

FIG.9illustrates a terminal60including a base160, a planar portion162connected to the base160, a tab164extending perpendicularly from an end of the planar portion162, a first wing166, a second wing168, a third wing170, and a fourth wing172. The first wing166, the second wing168, the third wing170, and the fourth wing172extend from the base160. The second wing168is spaced apart from the first wing166, the third wing170is disposed adjacent the first wing166, and the fourth wing172is spaced apart from the third wing170. In some instances, the planar portion162is welded (e.g., laser welded, ultrasonic welded) to an exposed conductor portion82of the flat cable40. The first wing166, the second wing168, the third wing170, and the fourth wing172are crimped to connect a wire50(e.g., a conventional round wire) with the terminal60. In some example configurations, the tab164is disposed in a recess116of the first cover90.

Referring again toFIGS.1and2, the electrical assembly20includes one or more clips150(e.g., clips150A,150B). The clips150secure the first cover90with the second cover92. In some example configurations, a second clip150B is arranged opposite a first clip150A.

FIG.8illustrates a clip150including a first leg152A, a second leg152B, a third leg152C, and a fourth leg152D. Referring now toFIG.2, in an assembled configuration, the first leg152A and the second leg152B are in contact with an outer side of the first cover90. The third leg152C is disposed in the first outer channel122A of the second cover92and the fourth leg152D is disposed in the second outer channel122B of the second cover92.

With reference toFIGS.1,2, and10, in some example configurations, the electrical assembly20includes a fastener180and a fastener bracket190. The fastener bracket190is configured for detachable connection with the housing30(e.g., the second cover92). The fastener180is configured for detachable connection with the fastener bracket190. Referring now toFIG.2, the fastener180is configured for connection with an external object200(e.g., a portion, a surface, and/or a component of a vehicle).

FIGS.11and12illustrate an electrical assembly20including a second housing30′ and a second flat cable40′. The second housing30′ is configured for connection with the housing30. The second housing30′ includes an identical configuration as the housing30. The second cable40′ is disposed at least partially in the second housing30′. The second housing30′ includes a second housing first cover90′ and a second housing second cover92′. In an assembled configuration, the second housing second cover92′ is stacked on and engaged with the first cover90of the housing30. In some instances, the second housing30′ is connected with the housing30such that a first attachment feature102A and a second attachment feature102B of the first cover90of the housing30are in contact with a first attachment structure130A′ and a second attachment structure130B′ of the second housing second cover92′.

FIGS.13-17present a method of assembling an electrical assembly20. The method includes disposing the dividers70(e.g., dividers70A-70E) in the inner channel122of the second cover92. The method includes crimping the wings (e.g.,166,168,170,172) of the terminals60(e.g., terminals60A-60D) to connect the wires50(e.g., wires50A-50D) with the terminals60. The method includes fixing (e.g., laser welding, ultrasonic welding) the planar portions162(e.g., planar portion162A-162D) of the terminals60to exposed conductor portions82(e.g., exposed conductor portions82A-82D) of the flat cable40(see, e.g.,FIG.13). The method includes disposing the flat cable40in contact with the second cover92such that the dividers70are disposed between adjacent terminals60(see, e.g.,FIG.14).

Referring now toFIG.15, the method includes connecting the first cover90with the second cover92. Referring now toFIG.16, the method includes connecting a first clip150A and a second clip150B to the housing30.

In some example configurations, the method includes disposing at least a portion of a second flat cable40′ in a second housing30′. The method includes stacking the second housing30′ on the housing30such that the second housing30′ is engaged with the housing30(see, e.g.,FIG.11).

With reference toFIGS.13-17, the method includes connecting a fastener bracket190to the housing30. The method includes connecting a fastener180to the fastener bracket190. The method includes connecting the assembly20with an external object200(see, e.g.,FIG.2).

This disclosure includes, without limitation, the following embodiments:1. An assembly, comprising: a housing; a flat cable disposed at least partially in the housing and including a first exposed conductor portion and a second exposed conductor portion; a first wire disposed partially in the housing; a second wire disposed partially in the housing; a first terminal disposed in the housing, the first terminal connected to the first exposed conductor portion and the first wire such that the first exposed conductor portion is electrically connected to the first wire; a second terminal disposed in the housing, the second terminal connected to the second exposed conductor portion and the second wire such that the second exposed conductor portion is electrically connected to the second wire; and a divider disposed between the first terminal and the second terminal, the divider formed separately from the housing.2. The assembly according to embodiment 1, wherein the housing includes a first cover and a second cover.3. The assembly according to any preceding embodiment, wherein the first cover includes: a planar base; a first attachment feature extending from a first side of the base; a second attachment feature extending from the first side of the base; a wall extending from a second side of the base; and a projection extending from the second side of the base and spaced apart from the wall.4. The assembly according to any preceding embodiment, wherein the projection includes a first part extending from the base and a second part extending parallel to and spaced apart from the base; and in an assembled configuration, portions of the first terminal and the second terminal are disposed in a recess disposed between the wall and the first part of the projection.5. The assembly according to any preceding embodiment, wherein: the second cover includes an inner channel; and the divider is partially disposed in the inner channel.6. The assembly according to any preceding embodiment, wherein: the second cover includes a first outer channel and a second outer channel; the inner channel is disposed between the first outer channel and the second outer channel; and the second cover includes a first attachment structure disposed in the first outer channel and a second attachment structure disposed in the second outer channel.7. The assembly according to any preceding embodiment, wherein the divider includes an elongated first portion and a second portion extending from the first portion; the first portion includes a length greater than a length of the second portion; and in an assembled configuration, the second portion is disposed in the inner channel of the second cover.8. The assembly according to any preceding embodiment, wherein in the assembled configuration, the divider is positively engaged with the inner channel of the second cover such that removal of the divider from the second cover is restricted.9. The assembly according to any preceding embodiment, including a clip; wherein the housing includes a first cover and a second cover; and the clip secures the first cover with the second cover.10. The assembly according to any preceding embodiment, wherein: the clip includes a first leg, a second leg, a third leg, and a fourth leg; in an assembled configuration, the first leg and the second leg are in contact with an outer side of the first cover; the third leg is disposed in a first outer channel of the second cover; and the fourth leg is disposed in a second outer channel of the second cover.11. The assembly according to any preceding embodiment, including a second clip arranged opposite the clip.12. The assembly according to any preceding embodiment, wherein the first terminal includes: a base; a first wing extending from the base; a second wing spaced apart from the first wing; a planar portion connected to the base; and a tab extending perpendicularly from an end of the planar portion.13. The assembly according to any preceding embodiment, wherein the planar portion is welded to the first exposed conductor portion of the flat cable and the tab is disposed in a recess of a first cover of the housing.14. The assembly according to any preceding embodiment, including: a third wire disposed partially in the housing; a third terminal disposed in the housing, the third terminal connected to a third exposed conductor portion of the flat cable and the third wire such that the third exposed conductor portion is electrically connected to the third wire; and a second divider disposed between the second terminal and the third terminal, the second divider formed separately from the housing and the divider; wherein the housing includes a first cover and a second cover; the divider and the second divider are partially disposed in and engaged with an inner channel of the second cover; tabs of the first terminal, the second terminal, and the third terminal are disposed at least partially in a recess of the first cover; and a first distance between the first terminal and the second terminal is different than a second distance between the second terminal and the third terminal.15. The assembly according to any preceding embodiment, including a fastener and a fastener bracket; wherein: the fastener bracket is detachably connected with the housing; the fastener is detachably connected with the fastener bracket; and the fastener is configured for connection with an external object.16. The assembly of according to any preceding embodiment, including: a second housing including an identical configuration as the housing; and a second flat cable disposed at least partially in the second housing; wherein the housing includes a first cover and a second cover; the second housing includes a second housing first cover and a second housing second cover; and the second housing second cover is stacked on and engaged with the first cover of the housing.17. The assembly of according to any preceding embodiment, wherein the second housing is connected with the housing such that a first attachment feature and a second attachment feature of the first cover of the housing are in contact with a first attachment structure and a second attachment structure of the second housing second cover.18. A method of assembling the assembly according to any preceding embodiment, comprising: disposing the divider at least partially in an inner channel of the second cover; fixing a planar portion of the first terminal to the first exposed conductor portion of the flat cable; fixing a planar portion of the second terminal to the second exposed conductor portion of the flat cable; disposing the flat cable in contact with the second cover such that the divider is disposed between the first terminal and the second terminal; and connecting the first cover with the second cover.19. The method according to embodiment 18, including: disposing at least a portion of a second flat cable in a second housing; and stacking the second housing on the housing such that the second housing is engaged with the housing.20. The method according to embodiment 18 or 19, including: connecting a fastener bracket to the housing; connecting a fastener to the fastener bracket; and connecting the assembly with an external object.

Various examples/embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples/embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the examples/embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the examples/embodiments described in the specification. Those of ordinary skill in the art will understand that the examples/embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to “examples, “in examples,” “with examples,” “various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, means that a particular feature, structure, or characteristic described in connection with the example/embodiment is included in at least one embodiment. Thus, appearances of the phrases “examples, “in examples,” “with examples,” “in various embodiments,” “with embodiments,” “in embodiments,” or “an embodiment,” or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more examples/embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope thereof.

It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of examples/embodiments.

“One or more” includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the various described embodiments. The first element and the second element are both element, but they are not the same element.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements, relative movement between elements, direct connections, indirect connections, fixed connections, movable connections, operative connections, indirect contact, and/or direct contact. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. Connections of electrical components, if any, may include mechanical connections, electrical connections, wired connections, and/or wireless connections, among others. Uses of “e.g.” and “such as” in the specification are to be construed broadly and are used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples.

While processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that such methods may be practiced with the steps in a different order, with certain steps performed simultaneously, with additional steps, and/or with certain described steps omitted.

As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

All matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the present disclosure.