WO2008157535A1 - Apparatus for conducting electrical energy - Google Patents

Apparatus for conducting electrical energy Download PDF

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Publication number
WO2008157535A1
WO2008157535A1 PCT/US2008/067202 US2008067202W WO2008157535A1 WO 2008157535 A1 WO2008157535 A1 WO 2008157535A1 US 2008067202 W US2008067202 W US 2008067202W WO 2008157535 A1 WO2008157535 A1 WO 2008157535A1
Authority
WO
WIPO (PCT)
Prior art keywords
conductors
insulation
cable
pin terminals
compliant pin
Prior art date
Application number
PCT/US2008/067202
Other languages
French (fr)
Inventor
Kevin P. Jokipil
Original Assignee
Trw Automotive U.S. Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Trw Automotive U.S. Llc filed Critical Trw Automotive U.S. Llc
Publication of WO2008157535A1 publication Critical patent/WO2008157535A1/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/51—Fixed connections for rigid printed circuits or like structures
    • H01R12/55—Fixed connections for rigid printed circuits or like structures characterised by the terminals
    • H01R12/58—Fixed connections for rigid printed circuits or like structures characterised by the terminals terminals for insertion into holes
    • H01R12/585—Terminals having a press fit or a compliant portion and a shank passing through a hole in the printed circuit board
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/023—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for transmission of signals between vehicle parts or subsystems
    • B60R16/027—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for transmission of signals between vehicle parts or subsystems between relatively movable parts of the vehicle, e.g. between steering wheel and column
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/592—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connections to contact elements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/14—Structural association of two or more printed circuits
    • H05K1/147—Structural association of two or more printed circuits at least one of the printed circuits being bent or folded, e.g. by using a flexible printed circuit
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
    • H01R35/02—Flexible line connectors without frictional contact members
    • H01R35/025—Flexible line connectors without frictional contact members having a flexible conductor wound around a rotation axis
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/05—Flexible printed circuits [FPCs]
    • H05K2201/051—Rolled
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10189—Non-printed connector
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/36—Assembling printed circuits with other printed circuits
    • H05K3/366—Assembling printed circuits with other printed circuits substantially perpendicularly to each other

Definitions

  • the present invention relates to a new and improved apparatus for use in conducting electrical energy.
  • the rotary connector may be a spirally wound flexible cable.
  • the cable may be a ribbon cable containing a plurality of conductors which are connected with terminals on the steering wheel and terminals connected with other apparatus in the vehicle.
  • the use of known rotary connectors is disclosed in U.S. Patent Nos. 6,776,634 and 6,994,557.
  • stampings require expensive custom tooling. If the stamping is insert- molded in plastic, additional expensive tooling is needed for the molding.
  • the present invention provides an apparatus for use in conducting electrical energy.
  • the apparatus includes a cable having a plurality of conductors which are at least partially enclosed by insulation. A portion of each conductor of the plurality of conductors is exposed through the insulation at a location offset from an end of the cable. A plurality of compliant pin terminals are connected with the conductors at locations where the conductors are exposed through the insulation.
  • FIG. 1 is a schematic illustration depicting the relationship between a steering wheel, an apparatus to conduct electrical energy, constructed in accordance with the present invention, and electrical circuitry in a vehicle;
  • Fig. 2 is a schematic end view, taken generally along the line 2-2 of Fig. 1, of a cable in the apparatus of Fig. 1;
  • Fig. 3 is a fragmentary schematic plan view, taken generally along the line 3-3 of Fig. 2, further illustrating the construction of the cable and the relationship of a plurality of compliant pin terminals to the cable;
  • Fig. 4 is a fragmentary schematic plan view, taken generally along the line 4-4 of Fig. 3, further illustrating a relationship of the compliant pin terminals to the cable;
  • Fig. 5 is an enlarged fragmentary schematic illustration depicting the manner in which openings are formed in the cable of Figs. 3 and 4 and the manner in which a compliant pin terminal is connected with a conductor in the cable at one of the openings;
  • Fig. 6 is a schematic side elevational view of a second embodiment of the apparatus to conduct electrical energy
  • Fig. 7 is a schematic plan view, taken generally along the line 7-7 of Fig. 6, illustrating a relationship between a plurality of compliant pin terminals and a cable in the apparatus of Fig. 6;
  • Fig. 8 is a schematic plan view, taken generally along the line 8-8 of Fig. 6, further illustrating the relationship of the compliant pin terminals to the cable.
  • a steering system 10 for use in turning steerable vehicle wheels (not shown) includes a steering wheel 12 which is connected with the steerable vehicle wheels.
  • the apparatus 14 accommodates rotation of the steering wheel 10 relative to the electrical circuitry 16.
  • the apparatus 14 functions as a rotary connector and includes a spirally wound flexible ribbon cable 22.
  • a plurality of compliant pin terminals 24 are provided at an inner end portion 26 of the ribbon cable 22 to connect the ribbon cable with electrical circuitry on the steering wheel 12.
  • a plurality of compliant pin terminals 30 are provided at an outer end portion 32 of the ribbon cable 22 (see Figs.2, 3 and 4) to connect the ribbon cable with the electrical circuitry 16 (Fig. 1) in the vehicle.
  • the ribbon cable 22 includes a plurality of flexible conductors 34 (Fig. 3) which extend between opposite ends of the ribbon cable 22.
  • the conductors 34 extend parallel to each other and are spaced from each other throughout the length of the ribbon cable 22.
  • the conductors 34 are enclosed by flexible insulation 36.
  • the conductors 34 and insulation 36 are both flexible so that the ribbon cable 22 can be wound in the manner illustrated schematically in Fig. 1.
  • the flexible insulation 36 has a rectangular cross sectional configuration with parallel major side surfaces 42 and 44 (Figs. 3 and 4).
  • the major side surfaces 42 and 44 extend between opposite ends of the ribbon cable 22.
  • the flexible conductors 34 are almost completely enclosed by the insulation 36.
  • the conductors 34 have been illustrated in Fig. 3 as extending beyond the insulation 36 at the left portion of the cable 22 (as viewed in Fig. 3), the insulation actually extends for the entire length of the cable and extends around the left end portions of the conductors as shown in Fig. 1.
  • the flexible conductors 34 are exposed through the insulation 36 at locations offset from an end 50 of the ribbon cable 22.
  • a plurality of spaced apart openings 54 (Figs.
  • Each of the identical openings 54 is spanned by an exposed portion of one of the conductors 34 (Fig. 5).
  • the illustrated openings 54 have a rectangular configuration. However, it is contemplated that the openings 54 may have a different configuration if desired. For example, the openings 54 may have a circular or oval configuration.
  • the openings 54 extend through the insulation 36.
  • the openings 54 extend between the opposite major side surfaces 42 and 44 of the insulation 36.
  • the openings 54 may only go partway through the insulation.
  • the openings 54 may extend from the major side surface 42 through a distance of approximately halfway to the opposite major side surface 44. If the openings 54 are formed so that they only extend partway through the insulation 36, the openings would have sufficient depth to expose the conductors 34 at the major side surface 42 of the ribbon cable 22.
  • each of the compliant pins 30 has a generally rectangular body portion 60 which is disposed adjacent to a longitudinally extending edge 62 of the ribbon cable 22.
  • Resiliently deflectable press fit portions 64 extend downward (as viewed in Figs. 3 and 4) from the body portions 60 of the compliant pins 30.
  • the press fit portions 64 of the compliant pins are pressed into openings in a socket.
  • the openings in a socket may be formed in a manner similar to the manner in which cylindrical openings 66 (Fig. 1) are formed in a socket 70.
  • the press fit portions 64 of the compliant pins 30 are pressed into the openings 66 to complete a path along which electrical energy may be conducted between the electrical circuitry 16 (Fig. 1) and the steering wheel 12 by the ribbon cable 22.
  • each of the compliant pins 30 includes an upwardly (as viewed in Figs. 3 and 5) extending connector portion 68.
  • the compliant pins are integrally formed from a single piece of metal and have a configuration generally similar to the configuration disclosed in U.S. Patent Nos. 7,083,434 and 7,008,272.
  • the compliant pins 30 may be formed with a different configuration and may be formed of two or more pieces of interconnected metal if desired.
  • the connector portions 68 of the compliant pins 30 are welded to the conductors 34 at the locations where the conductors are exposed in the openings 54.
  • a connector portion 68 of a compliant pin 30 has been illustrated in Fig. 5, it should be understood that a connector portion 68 of each compliant pin is welded to one of the conductors 34 at each of the openings 54. Although the connector portion 68 of each of the compliant pins 30 is connected to one of the conductors 34 by welding, it is contemplated that the complaint pins may be connected to the conductors 34 in a different manner if desired.
  • the longitudinally extending connector portions 68 of the compliant pins 30 have central axes which extend transverse to the longitudinal central axes of the conductors 34.
  • the longitudinal central axes of the connector portions 68 of the compliant pins 30 extend perpendicular to the longitudinal central axes of the conductors 34.
  • the connector portions 68 of the compliant pins 30 may be skewed relative to the conductors 34 so that the longitudinal central axes of the connector portions 68 of the compliant pins 30 would extend at an acute angle to the longitudinal central axes of the conductors 34.
  • the compliant pins 30 at the outer end portion 32 of the ribbon cable 22 have been illustrated in Figs. 2-5, it should be understood that the complaint pins 24 (Fig. 1) at the inner end portion 26 of the ribbon cable 22 are connected to the conductors 34 in the same manner as the compliant pins 30.
  • the compliant pins 24 are identical to the compliant pins 30 and have press fit portions which engage a socket mounted on the steering wheel 12 (Fig. 1) in the same manner as in which the compliant pins 30 engage the socket 70.
  • the compliant pins 24 are welded to the conductors 34 at openings in the insulation 36 in the same manner as previously described in conjunction with the compliant pins 30.
  • the compliant pins 30 are disposed in a linear array along a longitudinally extending edge 62 of the ribbon cable 22.
  • the compliant pins are disposed in a linear array along one end of a ribbon cable. Since the embodiment of the invention illustrated in Figs. 6-8 is generally similar to the embodiment of the invention illustrated in Figs. 2-5, similar numerals will be utilized to designate similar components, the suffix letter "a" being associated with the numerals of Figs. 6-8 to avoid confusion.
  • a flexible ribbon cable 22a has an end portion 32a on which a plurality of compliant pin terminals 30a are disposed in a linear array.
  • the ribbon cable 22a includes a plurality of flexible conductors 34a (Figs. 7 and 8). Each of the conductors 34a is connected to one of the compliant pins 30a at an opening 54a formed in flexible insulation 36a which encloses the conductors 34a.
  • the opening 54a is formed in the end portion 32a of the flexible ribbon cable 22a.
  • the opening 54a extends between opposite longitudinally extending edges 62a and 80 of the ribbon cable 22a.
  • the opening 54a is spanned by each of the conductors 34a.
  • the opening 54a extends perpendicular to a longitudinal central axis of the cable 22a.
  • the opening 54a extends through the insulation 36a. However, if desired, the opening 54a may extend only partway through the insulation 36a.
  • the compliant pins 30a are disposed in a linear array adjacent to an end 50a of the ribbon cable 22a.
  • Each of the compliant pins 30a includes a body portion 60a and a press fit portion 64a.
  • the body portions 60a are disposed in a linear array adjacent to the end 50a of the ribbon cable 22a.
  • a plurality of connector portions 68a extend from the body portions 60a of the identical compliant pins 30a and extend across the opening 54a.
  • Each of the connector portions 68a extends parallel to and is aligned with a conductor 34a. Each of the connector portions 68a is welded to the portion of a conductor 34a which is exposed at the opening 54a.
  • the compliant pins 34a at the end 50a of the ribbon cable 22a are disposed in an array which extends across the end of the ribbon cable (Figs. 7 and 8)
  • the opposite end of the ribbon cable 22a may be provided with an array of compliant pins which extends along one of the longitudinal edges of the ribbon cable 22a in the manner illustrated in Figs. 3 and 4.
  • the apparatus includes a cable 22 having a plurality 34 of conductors which are at least partially enclosed by insulation 36. A portion of each conductor 34 of the plurality of conductors is exposed through the insulation 36 at a location offset from an end of the cable. A plurality of compliant pin terminals 30 are connected with the conductors 34 at locations where the conductors are exposed through the insulation 36.

Abstract

An apparatus (14) for use in conducting electrical energy includes a cable (22) having a plurality (34) of conductors which are at least partially enclosed by insulation (36). A portion of each conductor is exposed through the insulation at a location offset from an end of the cable. A plurality (30) of compliant pin terminals are connected to the conductors (34) at locations where the conductors are exposed through the insulation (36). The conductors (34) may be exposed through the insulation (36) by forming one or more openings (54) in the insulation.

Description

APPARATUS FOR CONDUCTING ELECTRICAL ENERGY
Related Application
This application claims priority from U.S. Patent Application Serial No. 11/820,398, filed June 19, 2007. The subject matter of the aforementioned application is incorporated herein by reference in its entirety.
Background of the Invention
The present invention relates to a new and improved apparatus for use in conducting electrical energy.
Electrical switches and/or other devices mounted on a vehicle steering wheel have been connected with circuitry in the vehicle by a rotary connector
("clockspring"). The rotary connector may be a spirally wound flexible cable. The cable may be a ribbon cable containing a plurality of conductors which are connected with terminals on the steering wheel and terminals connected with other apparatus in the vehicle. The use of known rotary connectors is disclosed in U.S. Patent Nos. 6,776,634 and 6,994,557.
Commercially available connectors have been provided to connect ribbon cables with printed circuit boards. Some of these commercially available connectors use a mechanical clamping contact without metal bonding. Other commercially available connectors may use insulation displacement. Application specific stampings may be used to provide a connection from a ribbon cable to a printed circuit board.
However, these stampings require expensive custom tooling. If the stamping is insert- molded in plastic, additional expensive tooling is needed for the molding.
Summary of the Invention
The present invention provides an apparatus for use in conducting electrical energy. The apparatus includes a cable having a plurality of conductors which are at least partially enclosed by insulation. A portion of each conductor of the plurality of conductors is exposed through the insulation at a location offset from an end of the cable. A plurality of compliant pin terminals are connected with the conductors at locations where the conductors are exposed through the insulation. Brief Description of the Drawings
The foregoing and other features of the invention will become more apparent upon a consideration of the following description taken in connection with the accompanying drawings wherein: Fig. 1 is a schematic illustration depicting the relationship between a steering wheel, an apparatus to conduct electrical energy, constructed in accordance with the present invention, and electrical circuitry in a vehicle;
Fig. 2 is a schematic end view, taken generally along the line 2-2 of Fig. 1, of a cable in the apparatus of Fig. 1; Fig. 3 is a fragmentary schematic plan view, taken generally along the line 3-3 of Fig. 2, further illustrating the construction of the cable and the relationship of a plurality of compliant pin terminals to the cable;
Fig. 4 is a fragmentary schematic plan view, taken generally along the line 4-4 of Fig. 3, further illustrating a relationship of the compliant pin terminals to the cable; Fig. 5 is an enlarged fragmentary schematic illustration depicting the manner in which openings are formed in the cable of Figs. 3 and 4 and the manner in which a compliant pin terminal is connected with a conductor in the cable at one of the openings;
Fig. 6 is a schematic side elevational view of a second embodiment of the apparatus to conduct electrical energy;
Fig. 7 is a schematic plan view, taken generally along the line 7-7 of Fig. 6, illustrating a relationship between a plurality of compliant pin terminals and a cable in the apparatus of Fig. 6; and
Fig. 8 is a schematic plan view, taken generally along the line 8-8 of Fig. 6, further illustrating the relationship of the compliant pin terminals to the cable.
Description of Specific Preferred Embodiments of the Invention
A steering system 10 (Fig. 1) for use in turning steerable vehicle wheels (not shown) includes a steering wheel 12 which is connected with the steerable vehicle wheels. An apparatus 14, which is constructed in accordance with the present invention, is provided to conduct electrical energy between the steering wheel 12 and electrical circuitry 16 in the vehicle.
The apparatus 14 accommodates rotation of the steering wheel 10 relative to the electrical circuitry 16. The apparatus 14 functions as a rotary connector and includes a spirally wound flexible ribbon cable 22. A plurality of compliant pin terminals 24 are provided at an inner end portion 26 of the ribbon cable 22 to connect the ribbon cable with electrical circuitry on the steering wheel 12. Similarly, a plurality of compliant pin terminals 30 are provided at an outer end portion 32 of the ribbon cable 22 (see Figs.2, 3 and 4) to connect the ribbon cable with the electrical circuitry 16 (Fig. 1) in the vehicle.
The ribbon cable 22 includes a plurality of flexible conductors 34 (Fig. 3) which extend between opposite ends of the ribbon cable 22. The conductors 34 extend parallel to each other and are spaced from each other throughout the length of the ribbon cable 22. The conductors 34 are enclosed by flexible insulation 36. The conductors 34 and insulation 36 are both flexible so that the ribbon cable 22 can be wound in the manner illustrated schematically in Fig. 1.
The flexible insulation 36 has a rectangular cross sectional configuration with parallel major side surfaces 42 and 44 (Figs. 3 and 4). The major side surfaces 42 and 44 extend between opposite ends of the ribbon cable 22. The flexible conductors 34 are almost completely enclosed by the insulation 36. Although the conductors 34 have been illustrated in Fig. 3 as extending beyond the insulation 36 at the left portion of the cable 22 (as viewed in Fig. 3), the insulation actually extends for the entire length of the cable and extends around the left end portions of the conductors as shown in Fig. 1. In accordance with one of the features of the invention, the flexible conductors 34 are exposed through the insulation 36 at locations offset from an end 50 of the ribbon cable 22. To expose the conductors 34, a plurality of spaced apart openings 54 (Figs. 3-5) are formed in the insulation 36 at the inner and outer end portions 26 and 32 of the cable 22. Each of the identical openings 54 is spanned by an exposed portion of one of the conductors 34 (Fig. 5). The illustrated openings 54 have a rectangular configuration. However, it is contemplated that the openings 54 may have a different configuration if desired. For example, the openings 54 may have a circular or oval configuration.
The openings 54 extend through the insulation 36. Thus, the openings 54 extend between the opposite major side surfaces 42 and 44 of the insulation 36.
However, if desired, the openings 54 may only go partway through the insulation. Thus, the openings 54 may extend from the major side surface 42 through a distance of approximately halfway to the opposite major side surface 44. If the openings 54 are formed so that they only extend partway through the insulation 36, the openings would have sufficient depth to expose the conductors 34 at the major side surface 42 of the ribbon cable 22.
Once portions of the conductors 34 have been exposed at the openings 54, the compliant pins 30 are connected to the conductors 34. Each of the compliant pins 30 has a generally rectangular body portion 60 which is disposed adjacent to a longitudinally extending edge 62 of the ribbon cable 22. Resiliently deflectable press fit portions 64 extend downward (as viewed in Figs. 3 and 4) from the body portions 60 of the compliant pins 30. The press fit portions 64 of the compliant pins are pressed into openings in a socket. The openings in a socket may be formed in a manner similar to the manner in which cylindrical openings 66 (Fig. 1) are formed in a socket 70. The press fit portions 64 of the compliant pins 30 are pressed into the openings 66 to complete a path along which electrical energy may be conducted between the electrical circuitry 16 (Fig. 1) and the steering wheel 12 by the ribbon cable 22.
In addition, each of the compliant pins 30 includes an upwardly (as viewed in Figs. 3 and 5) extending connector portion 68. In the embodiment of the compliant pins 30 illustrated in Figs. 3-5, the compliant pins are integrally formed from a single piece of metal and have a configuration generally similar to the configuration disclosed in U.S. Patent Nos. 7,083,434 and 7,008,272. However, it should be understood that the compliant pins 30 may be formed with a different configuration and may be formed of two or more pieces of interconnected metal if desired. The connector portions 68 of the compliant pins 30 are welded to the conductors 34 at the locations where the conductors are exposed in the openings 54. Although only one connector portion 68 of a compliant pin 30 has been illustrated in Fig. 5, it should be understood that a connector portion 68 of each compliant pin is welded to one of the conductors 34 at each of the openings 54. Although the connector portion 68 of each of the compliant pins 30 is connected to one of the conductors 34 by welding, it is contemplated that the complaint pins may be connected to the conductors 34 in a different manner if desired.
The longitudinally extending connector portions 68 of the compliant pins 30 have central axes which extend transverse to the longitudinal central axes of the conductors 34. In the embodiment of the invention illustrated in Figs. 3-5, the longitudinal central axes of the connector portions 68 of the compliant pins 30 extend perpendicular to the longitudinal central axes of the conductors 34. However, if desired, the connector portions 68 of the compliant pins 30 may be skewed relative to the conductors 34 so that the longitudinal central axes of the connector portions 68 of the compliant pins 30 would extend at an acute angle to the longitudinal central axes of the conductors 34.
Although only the compliant pins 30 at the outer end portion 32 of the ribbon cable 22 have been illustrated in Figs. 2-5, it should be understood that the complaint pins 24 (Fig. 1) at the inner end portion 26 of the ribbon cable 22 are connected to the conductors 34 in the same manner as the compliant pins 30. The compliant pins 24 are identical to the compliant pins 30 and have press fit portions which engage a socket mounted on the steering wheel 12 (Fig. 1) in the same manner as in which the compliant pins 30 engage the socket 70. The compliant pins 24 are welded to the conductors 34 at openings in the insulation 36 in the same manner as previously described in conjunction with the compliant pins 30.
In the embodiment of the invention illustrated in Figs. 2-5, the compliant pins 30 are disposed in a linear array along a longitudinally extending edge 62 of the ribbon cable 22. In the embodiment of the invention illustrated in Fig. 7, the compliant pins are disposed in a linear array along one end of a ribbon cable. Since the embodiment of the invention illustrated in Figs. 6-8 is generally similar to the embodiment of the invention illustrated in Figs. 2-5, similar numerals will be utilized to designate similar components, the suffix letter "a" being associated with the numerals of Figs. 6-8 to avoid confusion.
A flexible ribbon cable 22a has an end portion 32a on which a plurality of compliant pin terminals 30a are disposed in a linear array. The ribbon cable 22a includes a plurality of flexible conductors 34a (Figs. 7 and 8). Each of the conductors 34a is connected to one of the compliant pins 30a at an opening 54a formed in flexible insulation 36a which encloses the conductors 34a.
The opening 54a is formed in the end portion 32a of the flexible ribbon cable 22a. The opening 54a extends between opposite longitudinally extending edges 62a and 80 of the ribbon cable 22a. The opening 54a is spanned by each of the conductors 34a. The opening 54a extends perpendicular to a longitudinal central axis of the cable 22a. The opening 54a extends through the insulation 36a. However, if desired, the opening 54a may extend only partway through the insulation 36a. The compliant pins 30a are disposed in a linear array adjacent to an end 50a of the ribbon cable 22a. Each of the compliant pins 30a includes a body portion 60a and a press fit portion 64a. The body portions 60a are disposed in a linear array adjacent to the end 50a of the ribbon cable 22a.
A plurality of connector portions 68a (Fig. 7) extend from the body portions 60a of the identical compliant pins 30a and extend across the opening 54a.
Each of the connector portions 68a extends parallel to and is aligned with a conductor 34a. Each of the connector portions 68a is welded to the portion of a conductor 34a which is exposed at the opening 54a. Although the compliant pins 34a at the end 50a of the ribbon cable 22a are disposed in an array which extends across the end of the ribbon cable (Figs. 7 and 8), the opposite end of the ribbon cable 22a may be provided with an array of compliant pins which extends along one of the longitudinal edges of the ribbon cable 22a in the manner illustrated in Figs. 3 and 4. In view of the foregoing description, it is apparent that the present invention provides a new and improved apparatus 14 for use in conducting electrical energy. The apparatus includes a cable 22 having a plurality 34 of conductors which are at least partially enclosed by insulation 36. A portion of each conductor 34 of the plurality of conductors is exposed through the insulation 36 at a location offset from an end of the cable. A plurality of compliant pin terminals 30 are connected with the conductors 34 at locations where the conductors are exposed through the insulation 36.

Claims

Having described the invention, the following is claimed:
1. An apparatus for use in conducting electrical energy, said apparatus comprising: a cable having a plurality of conductors which are at least partially enclosed by insulation, a portion of each conductor of said plurality of conductors being exposed through said insulation at a location offset from an end of said cable; and a plurality of compliant pin terminals each of which is connected to one of said conductors at a location where said one conductor is exposed through said insulation.
2. An apparatus as set forth in claim 1 wherein said cable has a plurality of spaced apart openings in said insulation, each of said openings being spanned by an exposed portion of one of said conductors of said plurality of conductors, each of said compliant pin terminals being connected to the exposed portion of one of said conductors which spans one of said openings in said insulation.
3. An apparatus as set forth in claim 2 wherein said insulation includes first and second major side surfaces which are disposed adjacent opposite sides of said plurality of conductors, each of said openings extends between said first and second major side surfaces of said insulation.
4. An apparatus as set forth in claim 2 wherein each of said compliant pin terminals includes a connector portion which spans one of said openings of said plurality of openings and is connected to a portion of one of said conductors of said plurality of conductors.
5. An apparatus as set forth in claim 4 wherein each of said compliant pin terminals includes a press fit portion, said press fit portions of said compliant pin terminals being disposed in a linear array along a longitudinally extending edge portion of said cable.
6. A apparatus as set forth in claim 1 wherein each of said compliant pin terminals includes a press fit portion which is resiliently deflectable when said press fit portion is inserted into an opening in a member to which said cable is to be connected and a connector portion which extends from said press fit portion and is connected to one of said conductors of said plurality of conductors.
7. An apparatus as set forth in claim 6 wherein said press fit portions of said compliant pin terminals are disposed in a linear array along a longitudinally extending edge portion of said cable and said connector portions of said compliant pin terminals extend transverse to longitudinal central axes of said conductors of said plurality of conductors.
8. An apparatus as set forth in claim 6 wherein said press fit portions of said compliant pin terminals are disposed in a linear array along the end portion of said cable and said connector portions of said compliant pin terminals extend parallel to portions of said conductors disposed in said end portion of said cable.
9. An apparatus as set forth in claim 1 wherein an elongated opening is formed in said insulation, said elongated opening being spanned by each of said conductors of said plurality of conductors, each of said compliant pin terminals being connected to the exposed portion of one of said conductors at said elongated opening in said insulation.
10. An apparatus as set forth in claim 9 wherein each of said compliant pin terminals includes a connector portion which spans said elongated opening and is connected to a portion of one of said conductors of said plurality of conductors at said elongated opening.
11. An apparatus as set forth in claim 10 wherein each of said compliant pin terminals includes a press fit portion, said press fit portions of said compliant pin terminals being disposed in a linear array along the end of said cable.
12. An apparatus as set forth in claim 9 wherein said insulation includes first and second major side surfaces which are disposed adjacent to opposite sides of said plurality of conductors, said elongated opening extends between said first and second major side surfaces of said insulation.
PCT/US2008/067202 2007-06-19 2008-06-17 Apparatus for conducting electrical energy WO2008157535A1 (en)

Applications Claiming Priority (2)

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US82039807A 2007-06-19 2007-06-19
US11/820,398 2007-06-19

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US20030199195A1 (en) * 2002-04-22 2003-10-23 Koehler David F. Electrical connector assembly and module incorporating the same
US7273393B2 (en) * 2003-08-29 2007-09-25 3M Innovative Properties Company Connector shell for a multiple wire cable assembly

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Publication number Priority date Publication date Assignee Title
EP2717386A1 (en) * 2012-10-06 2014-04-09 Valeo Schalter und Sensoren GmbH Connection unit for electrically connecting a coil spring with a circuit board, connection device, motor vehicle and corresponding method
DE102012019622A1 (en) * 2012-10-06 2014-04-10 Valeo Schalter Und Sensoren Gmbh Connection unit for electrically connecting a coil spring with a printed circuit board, connecting device, motor vehicle and corresponding method

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