Flat Cable Connector

Abstract

An electrical connector for flat cable, comprising a generally planar sheet metal base having a post receptacle extending generally normally of the base and at least one pair of ears defining a crimping ferrule struck from the base.

Description

The invention relates to a connector for a flat cable, by which is meant a cable having spaced generally coplanar conductors embedded in insulating laminae, as in ribbon and tape cable, or an insulated printed circuit comprising spaced conductors on a rigid or flexible insulating support with an insulating film on the exposed face of the conductor.

A problem with such flat cables is the need to remove insulation in connecting a conductor of the flat cable to a contact post.

An electrical connector for flat cable, according to the invention, comprises a generally planar sheet metal base having a post receptacle extending generally normally of the plane of the base and at least one pair of ears defining a crimping ferrule struck from the base at a side of the post receptacle.

Preferably the post receptacle is formed at or adjacent the midpoint of an elongate sheet metal base and a crimping ferrule is formed between a side of the post receptacle and each end of the elongate base so that the connector can be crimped to a conductor at two positions spaced longitudinally of the conductor. Preferably the connector is sufficiently wide to underlie and support the insulation lands on opposite sides of the conductor.

In a preferred method, a connector of the invention is so located adjacent a flat cable conductor that the crimping ears lie laterally of the conductor and are crimped to the cable by being forced through the lands and then folded over to contact the face of the conductor remote from the connector base. The flat cable so connected is advanced to a contact post, for example a contact pin extending from an instrument in a panel, and the post receptacle and contact post are force-fitted into telescopic engagement to connect the conductor of the flat cable and the contact post without stripping insulation from the flat cable.

The invention includes a connection formed of a flat cable and a connector of the invention, and also an assembly of the flat cable so connected and a contact post received in the post receptacle of the connector.

These and other objects, features and advantages of the present invention will be understood in greater detail from the following description and accompanying drawing:

FIG. 1 is a perspective view of a length of flat cable;

FIG. 2 is a perspective view of the invention; and

FIG. 3 is a perspective view of the connector of FIG. 2 crimped to the flat cable of FIG. 1.

The flat cable of FIG. 1 comprises generally coplanar electrically conductive tracks 1, preferably copper, embedded in and spaced apart by lands 2 of insulating material. Before the tracks 1 were sheathed some were punched with holes 3 in accordance with a pattern of contact posts, not shown, extending generally normally of a rear face of an instrument panel on which the flat cable is to be mounted, as explained below.

The connector of FIG. 2 is formed from sheet metal to comprise a flat base 4, generally rectangular in plan. A tubular post receptacle 5 is extruded from the base 4, upwardly as shown in FIG. 2, at or adjacent the center of the base. The receptacle 5 tapers away from the base 4 and the upper end of the receptacle 5 has short slits 6 extending towards the base. A crimping ferrule, generally indicated at 7, is formed from the body of the base 4 between the receptacle 5 and each shorter side of the base. Each ferrule 7 is of generally channel cross-section and comprises a pair of spaced apart ears 8 struck from the base, and lances 9 are struck up from the floor of the base between the ears 8. The upper edges of the ears may be sharpened. The crimping ferrules 7 may be of the type described and claimed in U.S. Pat. No. 3,395,381.

In use, connectors are so located under the flat cable that a receptacle 5 of each connector protrudes through a respective hole 3 and the crimping ears lie on opposite sides of the respective conductive track 1. The crimping ears 8 are then crimped to the track 1 by being pierced through the insulating lands 2 on opposite sides of the track 1, and then folded over to extend through the insulation overlying the track 1 electrically to contact the face of the track 1 remote from the base 4, the upper face as shown, and compress the track between the ears and the base. The flat cable so connected is then advanced to the rear face of an instrument panel, not shown, with the holes 3 in alignment with contact pins protruding from the rear face of the instruments and force-fitted on to the panel, so causing the receptacles 5 to be push-fitted over the contact pins, the slits 6 enhancing the engagement of the pins and receptacles. In this way the conductors of a flat cable are electrically connected to contact posts without impairing the insulation sheath of the cable.

The post receptacle 5 may be formed separately from the base 4 and then riveted to the base 4 to form a connector of the invention. The base 4 may be so shaped that, in use, the post receptacle 5 protrudes through an insulation land 2 instead of a hole 3 preformed in a track 1.

Claims

I claim:

1. An electrical connection comprising a strip of flat cable, an electrical connector secured to said cable and having a generally planar base formed from sheet metal, an opening in said cable and said connector for receiving a contact post, and means on said connector, on opposite sides of said connector opening, securing said connector to said cable, said means comprising a pair of ferrules crimped to a conductor of said flat cable.

2. An electrical connection as set forth in claim 1 further comprising a post receptacle extending generally normally of the base in alignment with said opening in the connector for receiving a contact post.

3. An electrical connection as set forth in claim 1 wherein a pair of ferrules are disposed at each of said opposite sides of said connector opening.

4. A method of applying a connector to flat cable wherein the connector comprises a generally planar sheet metal base having a post receptacle extending generally normally of the base and at least one pair of ears defining a crimping ferrule struck from the base, said method comprising so locating the connector with respect to the cable that the crimping ears underlie insulation lands on opposite sides of a conductive track, preforming a hole in the conductive track, inserting the post receptacle through the hole, and crimping the ears to the track by forcing the ears through the insulation lands and folding them to contact the face of the track remote from the connector base.