WO2007027593A1

WO2007027593A1 - Harness assembly with interconnect

Info

Publication number: WO2007027593A1
Application number: PCT/US2006/033509
Authority: WO
Inventors: Earl J. Hayes
Original assignee: 3M Innovative Properties Company
Priority date: 2005-08-31
Filing date: 2006-08-29
Publication date: 2007-03-08

Abstract

A harness assembly (10) includes a conduit (12) comprising an elongate body (14) having a first end (20), at least one conducting body (16), and insulating material (18) for insulating the at least one conducting body (16). The conduit (12) can be in the form of a flat flexible cable. A portion of the at least one conducting body (16) is exposed to define a receiving portion (30) by a laser etching process. An interconnect (24) includes a housing (26) and at least one interconnect pin (28) extending from a housing (26). The at least one interconnect pin (28) is electrically connected with the at least one conducting body (16) via the receiving portion (30). The housing (26) may comprise an overmold formed using a molding process that can be applied over a region (39) of the first end (20) of the conduit (12) to generally encapsulate the receiving portion (30) and a portion of the interconnect pin (28).

Description

HARNESS ASSEMBLY WITH INTERCONNECT

BACKGROUND

Field of the Invention

This invention relates in general to a harness and to a harness that includes a flat flexible conduit.

Description of the Related Art

Conventional harness assemblies generally consume considerable real estate. For example, without limitation, as technology evolves, the automotive industry generally offers a variety of devices and other related features within the vehicle. Typically, many of such devices include an electrical component or the like and, therefore, generally require a connection to at least one of a power source, a controller or the like. Each connection or grouping of connections generally includes a harness assembly to provide an electrical conduct for communication of such power, information or the like. Due to the multitude of electrical components within such confined areas, space therewithin has become a premium and, therefore, it is generally desirable to minimize the space of each harness assembly. Thus, it is desirable to limit the real estate occupied by such devices while maintaining, or even increasing, the reliability of the connection of the devices to the harness.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, embodiments of the invention are shown. The drawings are not necessarily to scale and certain features may be simplified or exaggerated to better illustrate and explain the invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise configurations shown in the drawings and disclosed in the following detailed description.

In the drawings:

Figure 1 shows a perspective view of a harness assembly according to an embodiment of the invention;

Figure 2 shows a top view of a harness assembly according to an embodiment of the invention; and Figure 3 shows a schematic view of a harness assembly according to an embodiment of the invention.

DETAILED DESCRIPTION Referring now to the Figures, an assembly according to the invention comprises a harness assembly, shown generally at 10, that includes a conduit 12 and an interconnect 24 attached thereto,

With reference to Figure 1, conduit 12 generally comprises an elongate body 14 having at least one conducting element or body 16 generally arranged within elongate body 14. Elongate body 14 may further include insulating means 18 that generally surrounds each conducting body 16 for insulating each conducting body 16 from each other and the external environment. Insulating means 18 may be made of any non- conductive material, for example, plastic, rubber, and the like. In an embodiment, conducting body 16 may be made of copper, however, it will be appreciated that conducting body 16 may comprise any type of electrically conductive material. Among other possibilities, conducting body 16 may comprise aluminum, another metal, a combination of metals, or any other type of conductive material.

For purposes of convenience, conduit 12 may be referred to as a flat flexible cable ("FFC") and/or include a flexible printed circuit ("FPC") within the FFC. It will be appreciated that other types of conduit are known and could be used, including without limitation, a ribbon cable, a wire or the like. The choice of such conduit may be application specific. For example, in a vehicular setting, among other factors, it is desirable to limit the real estate occupied by, and minimize the weight of, conduit 12. FFC or FPC of the type manufactured or licensed by Innovation Technology and distributed by, among other possibilities, I&T North America may be implemented to practice the invention.

Among other possibilities, conduit 12 may be adapted to transfer information, power or the like between one or more devices (not shown) arranged in communication with conduit 12. Among other examples, the one or more devices may be a power source, a controller, a component, an information source, or the like. In an embodiment, conduit

12 includes a first end 20 and a second end 21 (see Figure 3) wherein one or both first ends 20 and second end 21 includes an interconnect 24 to communicate with the one or more devices, as described below. Referring to Figure 1 and Figure 2, first end 20 includes interconnect 24 such that first end 20 may be configured to communicate with a device associated therewith. Referring to Figure 3, first end 20 and second end 21 each include interconnect 24 such that harness assembly 10 provides a communication means between two associated devices. These and other features will be further discussed hereinbelow.

For brevity, only the first end 20 of conduit 12 and the associated interconnect 24 will generally be discussed herein. It will be appreciated, however, that the principles relating to the assembly and structure of first end 20 described below, may be applied to second end 21 and an interconnect 24 associated therewith. Thus, the invention should not be limited to first end 20 such that both ends 20, 21 of conduit 12 may include interconnect 24.

With continued reference to the Figures, a region 39 of first end 20 of conduit 12 is a terminal end such that interconnect 24 facilitates electrical communication between one or more conducting bodies 16 of conduit 12 and the device associated with first end 20 via one or more interconnect pins 28. In the exemplary embodiment exhibited in the illustrations, conduit 12 includes four (4) conducting bodies 16 each having insulating means 18 generally disposed around each conducting body 16, and further wherein each conducting body 16 is associated with an interconnect pin 28. One of ordinary skill will recognize that interconnect pin 28 may be a bandolier pin, and the like. Further, although the Figures illustrate interconnect pin 28 extending through a housing 26, interconnect pin 28 may only extend into a portion of housing 26 and the present invention should not be limited to the illustrated embodiments. It will be appreciated that, in many environments, the reliability of the aforesaid communication between conduit 12, interconnect 24 and the device may be, generally, important in many applications. Among other examples, Figure 3 illustrates harness assembly 10 configured for a use in an environment, wherein a first body A associated with first end 20 of conduit 22 is a crash detection device and is connected to first end 20 of conduit 22 via interconnect 24. Similarly, a second body B associated with second end 20 of conduit 22 is a controller. In an embodiment, first body A generally communicates with second body B and outputs information to an air bag (not shown), and the like. Thus, the connections within this environment generally demand increase reliability.

Moreover, among other examples, it will further be appreciated, that many industries, such as the automotive industry, often generally provided guidelines or industry specific standards and the like. For example, with reference to the exemplary airbag connection discussed hereinabove, the automotive industry has termed the connection between the airbag and an associated controller a "clockspring harness" and has standardized the connection thereof. In an embodiment of the clockspring harness, first end 20 of conduit 12 and second end 21 of conduit 12 may each form terminal ends and each have an interconnect 24 associated therewith. It will be appreciated, that interconnect 24 may have various configurations, and an interconnect 24 associated with first end 20 of conduit 12 may have the same, or different, footprint as an interconnect 24 associated with second end 21 of conduit 12. Similarly, it will be appreciated that one or both of the ends 20, 21 may be a male end, a female end or a hybrid therebetween. In an embodiment, interconnect 24 may include a keyed portion (not shown) such that interconnect 24 may only structurally connect with an associated device (not shown) having an associated keyed portion (not shown). As briefly mentioned hereinabove, although the exemplary embodiment described comprises a clockspring harness, harness assembly 10 may be utilized in a variety of applications including the connection of devices, such as, radio controls, cruise control, and the like, to an associated component or controller. One of ordinary skill in the art will further recognize that the invention may be integrated into environments outside the automotive industry. That is, the invention may be practiced in any application wherein a harness assembly 10 including an interconnect 24 as described herein may be utilized. In an embodiment, interconnect 24 comprises a housing 26 and one or more interconnect pins 28 extending therefrom. Among other possibilities, at least one interconnect pin 28 is associated with at least one conducting body 16 within elongate body 14 of conduit 12. With reference to the Figures 1 and 2, each conducting body 16 of conduit 12 is associated with a corresponding interconnect pin 28 such that they form a one-to-one ratio. However, it will be appreciated that more than one conducting body 16 may be associated with a single interconnect pin 28, or more than one interconnect pin 28 may be associated with a single conducting body 16. Moreover, after considering the disclosure hereof, one of ordinary skill in the art will readily recognize that a interconnect pin 28 may not be associated with any conducting body 16 or vice-versa. Finally, it will be recognized that the number of interconnect pins 28 may not equal the number of conducting bodies 16 and the invention should not be so limited thereby.

Referring now to Figure 2, conduit 12 has a first dimension 33 associated therewith and interconnect pin 28 has a second dimension 35 associated therewith. In an embodiment, conduit 12 can be described as having a first centerline Y which may be associated with first dimension 33, and interconnect pin 28 can be described as having a second centerline Z which may be associated with second dimension 35. As illustrated, the first dimension may comprise a width of conduit 12 and the second dimension may comprise a width of the combination of one or more interconnect pins 28. However, it will be appreciated that other portions or descriptions of cable 16 and the combination of one or more interconnects pin 28 may be associated with the first dimension 33 and the second dimension 35 described herein, and the present invention should not be limited to the exemplary embodiment.

As described hereinabove, it will further be appreciated, that in many environments, among other factors, the space occupied by harness assembly 10 is generally a major consideration as space in many applications is often a premium. Thus, it may be generally desirable to minimize the space, or real estate, occupied by harness assembly 10. For example, in an embodiment, it may be desirable to reduce the size (i.e., width, length, height, or the like) of conduit 12 without comprising the reliability of harness assembly 10. In contrast, however, it will be appreciated that the combined width of the one or more interconnect pins 28 may be standardized such that the configuration or combined width of the one or more interconnect pins 28 may not be reduced. The invention provides means to connect the reduced width of conduit 12 with the standardized combined width of one or more interconnect pins 28. Although the present disclosure describes width of conduit 12 as being minimized, one of ordinary skill in the art will recognize that the invention should not be limited to the exemplary embodiment and conduit 12 and/or one or more interconnect pins 28 having any dimension may be used in accordance with the invention. Accordingly, it will be appreciated that first dimension 33, or the exemplary width associated with first center line Y of conduit 12 may be different than the second dimension 35, or the exemplary width associated with second centerline Z, of the combined one or more interconnect pins 28. Although the description hereof describes an exemplary embodiment wherein the first dimension 33 is different than the second dimension 35, it should be noted that the invention should not be limited thereby, and, in an embodiment, first dimension of conduit 12 may be the same as second dimension of interconnect pin 28 without deviating from the spirit and/or scope of the invention.

Conduit 12 defines an interconnect 24 at first end 20, as illustrated in the Figures. At least one conducting body 16 of conduit 12 includes at least one receiving portion 30. Receiving portion 30 may be developed about a portion of conducting body 16. Among other factors, the position, number, size or the like of receiving portion 30 may be application-specific and one of ordinary skill of the art will recognize the benefits realized by varying these factors, among others, and the present invention should not limited to the exemplary embodiment illustrated and described.

Referring now to Figure 1 and Figure 2, there are four of such receiving portions

30 developed about four conducting bodies 16. Receiving portions 30 can be arranged in a diagonal fashion or in an offset relationship, however, the invention should not be limited to the illustrated arrangement and the receiving portions may be located about the same lateral position of conducting body 16.

To define receiving portion 30, first end 20 of conduit 12 is arranged to overlie at least one interconnect pin 28 such that the associated conducting body 16 becomes generally aligned with its respective interconnect pin 28. In an embodiment, receiving portion 30 may be defined by using a laser, such that a window 31, and the like, is formed to provide a means to access interconnect pins 28 and electrically attach receiving portion 30 of conducting body 16 to the appropriate interconnect pin 28. Without limitation, a laser etching process may be used to remove a portion of insulating means 18 resident over and under conducting body 16 such that a portion of conducting body 16 generally becomes exposed and interconnect pin 28 may be electrically attached thereto. After considering the present disclosure, one of ordinary skill in the art will readily recognize the benefits realized from the laser process. Among other general efficiencies resulting from the laser process, the position, size, configuration, arrangement or the like of receiving portion 30 may be changed without having to significantly re-tool a manufacturing environment. For example, without limitation, the laser process may be modified to re-define the process in accordance with the new first dimension and/or the second dimension of conduit 12 and/or interconnect pin 28.

Interconnect pin 28 may be attached to a corresponding receiving portion 30 of conducting body 16 using an attachment means via window 31. In an embodiment, a portion of interconnect pin 28 may be soldered, welded, and the like, to receiving portion 30 such that a reliable electrical path is formed between interconnect pin 28 and conducting body 16. In an embodiment, a securing fixture (not shown) may be utilized to generally retain conduit 12 and the associated interconnect pin 28 to generally align and retain receiving portion 30 of conducting body 16 with interconnect pin 28. In an embodiment, securing fixture (not shown) may be a two-piece device generally held together by a clamp (not shown) or the like. However, securing fixture (not shown) may be a one-piece housing or include more than two-pieces, and the present invention should not be limited to the exemplary embodiments described herein.

In an embodiment, the application of heat to the generally aligned interconnect pin 28 and receiving portion 30 of conducting body 16 via window 31 mechanically and electrically secures the connection therebetween. In an embodiment, the receiving portion 30 becomes bonded or welded to interconnect pin 28. It will be appreciated that other methods may secure the mechanical and electrical connection, including without limitation, disposing solder therebetween. For example, a solder ball may be disposed between the receiving portion 30 and corresponding interconnect pin 28, or a interconnect pin 28 may include solder, such that upon a reflow process the electrical connection becomes mechanically secured.

In an embodiment, the assembly described hereto comprising interconnect pin 28 and receiving portion 30 (welded or otherwise) may then be removed from securing fixture such that housing 26 may be applied thereover to form interconnect 24 at first end 20. In an embodiment, housing 26 is formed using a molding process. For example, in an embodiment, housing 26 comprises an overmold that can be applied over first end 20 of conduit 12 to generally encapsulate one or more of the receiving portions 30, a portion of interconnect pin 28, and a region 39 of conduit 12. One of ordinary skill in the art will recognize various manufacturing techniques to apply overmold and form housing 26. In an exemplary embodiment, overmold is formed using an injection molding process, wherein overmold is a polyolefin material, such as a thermoplastic or the like. Among other examples, the injection molding process may utilize a high heat, low-pressure process; a low heat, high pressure process; or a combination thereof. Further, it will be appreciated, that other materials and other molding processes may be used to form overmold.

It should be noted that harness assembly 10 may further include a tension limiting means or strain relief means 38 or tension limiting means such that, upon the application of tension to interconnect 24, strain relief means 38 displaces at least a portion of the tension exerted to protect unwanted damage to harness assembly 10. Specifically, strain relief means 38 may generally shield or protect the connection between interconnect pin 28 and receiving portion 30 of conduit 12. In an embodiment, conduit 12 generally includes the strain relief means 38 defined within region 39 of conduit 12. Referring to Figure 2, conduit 12 may include a notch or indentation 40 or a pair of notches or indentations 40, 42 at opposite sides of conduit 12 such that upon application of housing 26, the indentations 40 become generally filled by the housing material such that a flange or flanges 44, 46 are formed therein. One of ordinary skill in the art will recognize that one indentation 40 or a plurality of indentation will be utilized. Further, indentation 40, 42 and thus, flanges 44, 46, may not directly oppose each other. Further, it will be appreciated, that upon stress or tension applied to a portion of conduit 12, the flanges 44, 46 act to resist the transfer of such tension to the connection between receiving portion 30 of conducting body 16 and interconnect pin 28 and displace the tension into housing 26. Moreover, after considering the present disclosure, one of ordinary skill will appreciate that other geometries may be formed within region 39 of conduit 26 to displace tension or stress as described, and provide additional or substitute strain relief means 38. For example, referring to Figure and Figure 2, strain relief means 38 may comprise an aperture 48 formed within an area of portion 39 of conduit 12 in accordance with the principles described above. These and other features, and arrangements, of strain relief means 38 will become readily apparent to one of ordinary and, therefore, the invention should not be limited to the disclosed,. exemplary embodiment.

The present invention has been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention. It should be understood by those skilled in the art that various ^' alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description of the invention should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non- obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or single element is essential to all possible combinations that may be claimed in this or a later application.

Claims

CLAIMSWhat is claimed is:

1. A harness assembly ( 10), comprising: a conduit (12) comprising an elongate body (14) having a first end^' (20), at least one conducting body (16), and insulating means (18) for insulating the at least one conducting body (16), a portion of the at least one conducting body (16) being exposed to define a receiving portion (30); and an interconnect (24) comprising a housing (26) and at least one interconnect pin (28) extending from the housing (26), the at least one interconnect pin (28) being electrically connected with the at least one conducting body (16) via the receiving portion (30).

2. The harness assembly (10) according to Claim 1, wherein the receiving portion (30) comprises a window (31) formed by a laser etching process.

3. The harness assembly (10) according to Claim 1, further comprising a strain relief means (38) formed in the insulating means (18) of the conduit (12).

4. The harness assembly (10) according to Claim 3, wherein the strain relief means (38) comprises a notch or aperture (40, 42, 48) formed in the insulating means

(18).

5. The harness assembly (10) according to Claim 1, wherein the housing (26) comprises an overmold formed over a region (39) of the first end (20) of the conduit (12) to generally encapsulate the receiving portion (30) and a portion of the at least one interconnect pin (28).

6. The harness assembly (10) according to Claim 1, wherein the conduit (12) includes a plurality of conducting bodies (16) and a corresponding number of receiving portions (30), and wherein the interconnect (24) includes a corresponding number of interconnect pins (28) electrically connected to the plurality of conducting bodies (16) in a one-to-one correspondence via the corresponding number of receiving portions (30).

7. The harness assembly (10) according to Claim 6, wherein the receiving portions (30) are arranged in an offset relationship.

8. A harness assembly (10), comprising: a flat flexible cable (12) comprising an elongate body (14) having a first end (20), at least one conductor (16), and insulating means (18) for insulating the at least one conductor (16), a portion of the at least one conducting body (16) being exposed to define a receiving portion (30); and an interconnect (24) comprising a housing (26) and at least one interconnect pin (28) extending from the housing (26), the at least one interconnect pin (28) being electrically connected with the at least one conducting body (16) via the receiving portion (30).

9. The harness assembly (10) according to Claim 8, wherein the receiving portion (30) comprises a window (31) formed by a laser etching process.

10. The harness assembly (10) according to Claim 8, further comprising a strain relief means (38) formed in the insulating means (18) of the flat flexible cable (12).

11. The harness assembly (10) according to Claim 10, wherein the strain relief means (38) comprises a notch or aperture (40, 42, 48) formed in the insulating means (18).

12. The harness assembly (10) according to Claim 8, wherein the housing (26) comprises an overmold formed over a region (39) of the first end (20) of the flat flexible cable (12) to generally encapsulate the receiving portion (30) and a portion of the at least one interconnect pin (28).

13. The harness assembly (10) according to Claim 8, wherein the flat flexible cable (12) includes a plurality of conducting bodies (16) and a corresponding number of receiving portions (30), and wherein the interconnect (24) includes a corresponding number of interconnect pins (28) electrically connected to the plurality of conducting bodies (16) in a one-to-one correspondence via the corresponding number of receiving portions (30).

14. The harness assembly (10) according to Claim 13, wherein the receiving portions (30) are arranged in an offset relationship.

15. A method of making a harness assembly (10) including a conduit (12) comprising an elongate body (14) having a first end (20), at least one conducting body (16), and insulating means (18) for insulating the at least one conducting body (16); and an interconnect (24) comprising a housing (26) and at least one interconnect pin (28) extending from housing (26), the method comprising the steps of: exposing a portion of the at least one conducting body (16) to form a receiving portion (30) at the first end (20) of the conduit (12); aligning the receiving portion (30) of the at least one conducting body (16) with the at least one interconnect pin (28) of the interconnect (24); and electrically connecting the at least one interconnect pin (28) of the interconnect

(24) with the at least one conducting body (16) of the conduit (12) via the receiving portion (30).

16. The method of Claim 15, further comprising the step of molding the housing (26) over a region (39) of the first end (20) of the conduit (12) to generally encapsulate the receiving portion (30) and a portion of the at least one interconnect pin (28).

17. The method of Claim 15, further comprising the step of forming a strain relief means (38) in the insulating means (18) of the conduit (12).

18. The method of Claim 15, wherein the receiving portion (30) is formed by a laser etching process