GB2393930A

GB2393930A - A flatwire conductor

Info

Publication number: GB2393930A
Application number: GB0329990A
Authority: GB
Inventors: Hong Zhou; Ii Richard Keith Mcmillan
Original assignee: Visteon Global Technologies Inc
Current assignee: Visteon Global Technologies Inc
Priority date: 2001-09-20
Filing date: 2002-07-31
Publication date: 2004-04-14
Also published as: GB2393680A; GB0329990D0; GB0329987D0

Abstract

A flatwire 10 conductor/cable arranged so that when more than one flatwire 10 conductors/cables are re-connected or connected they constitute a plurality of sections where at least one portion is a re-connection or connection region. The flatwire 10 conductor/cable is also associated with an alignment means 18 and incision of the insulator.

Description

GB 2393930 A continuation (74) Agent and/or Address for Service: Dummett

Copp 25 The Square, Martlesham Heath, IPSWICH, Suffolk, IP5 3SL, United Kingdom

- 1 FLATWIRE CUT-TO-SERVICE METHOD AND APPARATUS

The present invention relates to flatwire connections and devices and methods for repairing damages flatwire cables 5 and associated connectors.

In an ongoing effort to reduce cost and approve reliability in vehicle electrical and electronic systems, flatwire conductors having nonseparable connections have 10 gained wide spread use. One significant drawback in using non-separable connections in flatwire is the difficulty in servicing and repairing the flatwire.

One prior art service method is to cut the flatwire,

15 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

20 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.

25 Consequently, additional damage to the vehicle system frequently occurs.

Therefore, there exists a need for a new and improved service method and system for cutting flatwire and 30 removing the damaged portions. The new and improved method should dispense with unique service parts and 3467p4c December 22, 2003

facilitate remanufacturing of the defective/damaged part as well as reuse of the service tool.

According to a first aspect of the present invention 5 there is provided a flatwire conductor comprising a plurality of conductors received within an insulator and a plurality of sections and one or more re-connection regions, each section being separated from an adjacent section by a reconnection region, each re-connection 10 region being associated with an alignment means and an incision in the insulator.

Further aspects, features and advantages of the invention will become apparent from consideration of the following 15 description and the appended claims when taken in

connection with the accompanying drawings.

Figure 1 is a top view of a flatwire segment, in accordance with the present invention; 20 Figure 2a-2b is front and side views of a cutting tool for cutting a flatwire segment, in accordance with the present invention; and Figure 3a-3e are perspective views of another embodiment of a cutting tool for cutting flatwire, 25 in accordance with the present invention.

Reference is now made to Figure 1 wherein a flatwire electrical conduit 10 is illustrated, in accordance with the present invention. Flatwire 10 includes a plurality 30 of conductors 12 for transmitting electrical signals to various parts of an electronic system. Typically, 3467p4c December 22, 2003

- 3 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) 5 is a Dupont trade name for PET.

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 10 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 15 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 20 inserted in place thereof.

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.

25 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.

3467p4c Decerrber 22, 2003

Referring now to Figure 2a, an embodiment of the cutting tool 30 is illustrated, in accordance with the present invention. Figure 2a is a front view of cutting tool 30 illustrating a blade 32 fixedly mounted to a upper clamp 5 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.

10 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 15 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.

A cross-sectional view, at a location indicated in Figure 2a, of the flatwire 10 disposed within cutting tool 30 is illustrated in Figure 2b, in accordance with the present invention. In operation, flatwire 10 is positioned 25 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 30 clamp member 34 toward lower clamp member 36 and eventually causing cutting blade 36 to shear flatwire 10 3467p4c December 22, 2003

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 5 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 10 of the flatwire 10.

Referring now to Figure 3a through Figure Be, an alternative embodiment of cutting tool 30 is illustrated, in accordance with the present invention. Alternative 15 cutting tool 30'' includes a top plate 80 shown in Figure 3a, and a bottom plate 100 shown in Figure 3d. 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 20 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 25 86. Further, top plate 80 includes a pair of apertures 91 for receiving screws 92 (shown in Figure 3c). Screws 92 are used to removeably attach the top plate 80 to bottom plate 100, as will become apparent hereinafter.

30 Figure 3c is a bottom perspective view of top plate 80.

In addition to further illustrating cutter block 86, 3467p4c December 22, 2003

- 6 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 Figure 3d, to 5 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.

With specific reference to Figure ad, bottom plate 100 is 10 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 15 blade 90.

In operation, alternative cutting tool 30" is secured to flatwire 10, as shown in Figure 3e. By aligning the top plate 80 over the bottom plate 100 and securing bottom 20 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 Figure 1). The resulting assembly, that is the second flatwire portion and 25 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 30 connector may have a replacement flatwire portion, having a length equal to the flatwire portion that was removed.

3467p4c December 22, 2003

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 5 replacing damaged portions of a flatwire. Moreover, the present invention provides a system and method for recycling flatwire and flatwire cutting tools.

The foregoing discussion discloses and describes a 10 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 15 invention as defined in the following claims.

3467p4c December 22, 2003

Claims

- 8 CLAIMS

1. A flatwire conductor comprising a plurality of conductors received within an insulator and a plurality 5 of sections and one or more reconnection regions, each section being separated from an adjacent section by a re-

connection region, each re-connection region being associated with an alignment means and an incision in the insulator. 3467p4c December 22, 2003