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Anonymous Poster

Flex to cable connection

06/20/2007 11:15 AM

I have a question regarding manufacturing. Our design team is working on a product that needs to connect a Flex (2 terminals) to a cable. The flex is like 3 or 4 mm wide x 15 cms +/- long (like a strip of very thin tape). We have to connect in one of the ends to 2 jumpers cables (gage I think 30). First we tried solder lap and the flex burned, so we tried through holes but the cables are too big and we are having a tough time connecting this SOB because the flex is flexible (LOL) and it moves each time we need to connect and If you are a manufacturing engineer you know that when we kick this baby up to a 1000 a day = major scrap $$$. So the other option we have is to use a connector BUT THIS IS VERY EXPENSIVE so we need a cost effective solution to this.

ANY IDEAS??

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Guru
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#1

Re: Flex to cable connection

06/20/2007 12:11 PM

If solder won't work, what about in-line crimps?

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#2

Re: Flex to cable connection

06/21/2007 2:59 AM

Try investigating conductive adhesive, also consider swaged terminals or maybe both depends on application and the quality standard that you have to comply with !!

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Guru

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#3

Re: Flex to cable connection

06/21/2007 3:06 AM

We used to use braided straps up to 3 inches wide and 1/4 inch thick. 2 methods worked, forming it into a circular shape and crimping it with a traditional "Burndy" lug.

The other was 2 flat copper "clam shells" that were formed over the braid, put in a press and riveted through the sides, solder dipped with a rosin flux, holes punched for bolted connection.

Your very small dimensions should crimp in a commercial connector. If you are burning off the shunt I would be concerned the shunt is undersized.

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