Cable Connection Structure Groove Protrusions
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Solution Overview
Problem
Existing cable connection methods risk damaging conductor parts due to pressure and shifting during soldering, leading to connection failures and short-circuits.
Innovation Solution
A cable connection structure featuring protrusions on the connection electrode that form a groove for the conductor part, where the height of the protrusions is greater than the diameter of the conductor, preventing squashing and shifting during bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat tool is pushed against the connection between the connection electrode and the conductor part to heat and melt solder for bonding, then the connection electrode and the conductor part are bonded, but the conductor part may be squashed or shifted due to the pressure of the heat tool
Solution Approach 1:
The connection electrode is segmented into multiple protrusions that form a groove structure. This segmentation allows the conductor part to be positioned in the groove formed between the protrusions, providing mechanical support and preventing squashing while allowing solder to flow around the protrusions for reliable bonding.
Solution Approach 2:
The groove structure is formed in advance on the connection electrode before the bonding process. This preliminary action of creating the groove ensures that the conductor part is properly positioned and supported before heat and pressure are applied, preventing shifting and squashing during the bonding operation.
2Ease of manufacture
If the conductor part is squashed due to heat tool pressure, then soldering can be completed, but a break and short-circuit may occur due to decreased strength
Solution Approach 1:
The groove structure formed by the protrusions acts as a cushioning structure that absorbs and distributes the pressure from the heat tool before it reaches the conductor part. This beforehand cushioning prevents the conductor part from being squashed, maintaining its strength and preventing breaks and short-circuits during the soldering process.
3Manufacturing precision
If grooves are formed by etching cable connection electrodes on a substrate to position core wire and shielded wire, then the coaxial cable can be connected to a given position without being shifted, but the conductor part may still be subjected to pressure during soldering
Solution Approach 1:
Instead of forming grooves by etching (two-dimensional surface modification), the invention uses three-dimensional protrusions that extend vertically from the substrate surface. This dimensional change provides deeper mechanical support for the conductor part, preventing both shifting (positioning accuracy) and squashing (strength preservation) during soldering.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures stable connection of fine cables to a narrow area without applying load to the conductor, reducing connection failures and stress on the conductor parts, making it suitable for applications like endoscopes and ultrasonic imaging systems.
Implementation Method 1
the substrate comprises two or more protrusions, on the connection electrode, that form a groove in which a conductor part of the cable is arranged
Data Source
AI summary
A cable connection structure includes a cable and a substrate that includes a connection electrode to which the cable is connected. The substrate includes two or more protrusions that form a groove in which a conductor part of the cable is arranged. The height of the protrusions is greater than the diameter of the conductor part of the cable.