Method and System for Coupling a Conductive Substrate to a Ribbon Cable

Abstract

Devices and methods are disclosed for coupling a multi-conductor cable to a flexible substrate by means of a crimp.

1 . A method of coupling a conductive substrate to a cable, the method comprising the steps of; a. providing a multi-conductor, insulated electrical cable, b. providing an electrically conductive substrate including for instance an electrically conductive fabric; c. providing a wire crimp composed of electrically conductive material wherein a first portion of the crimp is sized and shaped to puncture the insulation of and tap into at least one of the conductors of the cable, a second portion of the crimp is sized and shaped to mechanically couple the crimp to the substrate, and a third portion of the crimp is sized and shaped to mechanically couple the crimp to the cable; d. positioning the crimp above a specific conductor of the cable; e. positioning the substrate one of between the cable and the crimp, above the crimp and cable, or below the crimp and the cable; f driving the crimp into the cable, thereby puncturing the substrate and creating an electrical and mechanical connection between the conductor, the substrate, and the crimp. 
     
     
         2 . The method of  claim 1 , wherein the cable is a flat ribbon cable. 
     
     
         3 . The method of  claim 1 , wherein first portion of the crimp is selected from one of a flat ventral-facing edge, a sharp ventral-facing point, or a ventral-facing barb. 
     
     
         4 . The method of  claim 1 , wherein the second portion of the crimp is selected from one of a substantially laterally extending barb, a substantially axially extending barb, or a bridge between two laterally opposed tines. 
     
     
         5 . The method of  claim 1 , wherein the third portion of the crimp is selected from one of a substantially medially extending barb or a deformable portion that is engaged about the conductor against an anvil during the driving process. 
     
     
         6 . The method of  claim 1 , wherein the third portion of the crimp is driven into a retaining plate disposed upon the opposing face of the cable, thereby creating a shackle. 
     
     
         7 . The method of  claim 1 , wherein a single driving action acts upon multiple crimps at the same time. 
     
     
         8 . The method of  claim 1 , wherein the crimp is driven by a pneumatic, hydraulic, or electric actuator. 
     
     
         9 . The method of  claim 1 , wherein the second portion of the crimp defines electrical communication between the substrate and the crimp. 
     
     
         10 . the method of  claim 1 , wherein the crimp is subsequently deformed to urge the substrate and wire against one another. 
     
     
         11 . A system for mechanically and electrically coupling a planar conductive substrate to a multi-conductor insulated cable using a wire crimp, the system comprising; a substantially planar backplate, a driver which travels along an axis normal to the backplate wherein the driver is sized and shaped to urge a wire crimp through the substrate and cable, a carrier for positioning the wire crimp over a specific conductor of the cable before it is driven therethrough; wherein the wire crimp has (a) a first protrusion which pierces the insulation surrounding a single conductor of the cable to provide electrical coupling between the conductor and the substrate as the crimp is acted upon by the driver, and (b) a second protrusion which is deformed against the backplate to become engaged about the cable thereby providing mechanical coupling between substrate and the cable. 
     
     
         12 . The system of  claim 11 , wherein the backplate has longitudinal grooves thereupon which deform laterally opposing tines of a wire crimp about a conductor when the crimp is driven thereagainst. 
     
     
         13 . The system of  claim 11 , wherein the carrier is capable of being translated laterally while the lateral position of the cable is fixed. 
     
     
         14 . The system of  claim 11 , wherein the second protrusion is sized and shaped so as not to come into contact with the conductor when being acted upon by the driver. 
     
     
         15 . The system of  claim 11 , wherein the second protrusion is sized and shaped to travel in the space between conductors of the ribbon cable when the crimp is acted upon by the driver. 
     
     
         16 . The system of  claim 13 , wherein the lateral translation is provided by one of, replaceable carriers which precisely position the carried over a specific conductor, an electronically driven linear actuator which translates the carrier laterally, a manually adjustable linear actuator which translates the carrier laterally. 
     
     
         17 . The system of  claim 11 , wherein there is a secondary driver which translates a clamp along an axis normal to the backplate thereby selectably fixing the ribbon between the backplate and the clamp. 
     
     
         18 . The system of  claim 11 , wherein there is a secondary driver which translates a clamp along an axis normal to the backplate which holds the substrate in place against the ribbon.