Cable Assembly Fixing Block for Braiding Layer Slip Prevention
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Solution Overview
Problem
The existing cable connectors face issues with the braiding layer sliding on the covering layer due to weak adhesion, leading to shrinkage during processing, affecting appearance and functionality.
Innovation Solution
A fixing block is injection-molded onto the braiding layer, with its material partially penetrating into the braiding layer to integrate it with the covering layer, enhancing their fixation and preventing sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a braiding layer is wrapped on the covering layer to improve appearance and protection, then the cable assembly gains better structural integrity and aesthetics, but the braiding layer slides on the covering layer due to weak adhesion, causing shrinkage during processing
Solution Approach 1:
The fixing block merges the braiding layer and covering layer into a unified structure by penetrating through both layers and anchoring them together. This integration prevents relative sliding between layers while maintaining their individual protective functions, directly resolving the adhesion problem.
Solution Approach 2:
The fixing block acts as an intermediary element between the braiding layer and covering layer. It provides a mechanical connection medium that compensates for the insufficient natural adhesion between these two layers, enabling stable integration without compromising their respective properties.
2Adaptability or versatility
If the braiding layer is made soft with strong scalability to improve flexibility and fit, then the cable assembly becomes more adaptable to different configurations, but the adhesion between the braiding layer and covering layer becomes very small, leading to sliding
Solution Approach 1:
The fixing block combines the soft, scalable braiding layer with the covering layer into a single integrated unit. This merging allows the braiding layer to maintain its flexibility and adaptability while the fixing block provides the necessary mechanical strength to prevent sliding between layers.
Solution Approach 2:
The solution creates a composite structure consisting of the soft braiding layer, the covering layer, and the fixing block material. This composite approach allows each component to contribute its advantageous properties - the braiding layer provides scalability, the covering layer provides protection, and the fixing block provides structural strength.
3Ease of operation
If the braiding layer is allowed to slide freely on the covering layer to maintain flexibility, then the cable assembly remains flexible and easy to install, but shrinkage occurs during the front-end processing stage, affecting appearance and function
Solution Approach 1:
The fixing block applies localized constraint at specific positions where sliding would cause dimensional issues during manufacturing. The cable assembly maintains flexibility in non-constrained regions while the fixing block provides precise dimensional control at critical locations, resolving the contradiction between flexibility and manufacturing precision.
Solution Approach 2:
The fixing block is installed in advance during the manufacturing process to prevent shrinkage before the cable assembly is put into service. This preliminary action ensures that the cable maintains its intended dimensions and appearance during critical front-end processing stages while preserving flexibility for end-use installation.
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
The integration of the braiding and covering layers through the fixing block ensures tight fixation, preventing shrinkage and improving structural reliability and ease of connection to circuit boards.
Implementation Method 1
injecting a liquid filling material into the injection port so that the liquid filling material is injected into the molding groove through the injection runner, and the liquid filling material penetrates into the braiding layer
Implementation Method 2
a material of the fixing block at least partially penetrating into the braiding layer so as to integrate the braiding layer and the covering layer into a whole
Data Source
AI summary
A cable assembly includes a number of wires, a covering layer, a braiding layer and a fixing block. Each wire includes a core for conducting electricity and an insulating layer wrapped on the core. The covering layer is wrapped on the plurality of wires. The braiding layer is wrapped on the covering layer. The fixing block is injection-molded on the braiding layer. A material of the fixing block at least partially penetrates into the braiding layer so as to integrate the braiding layer and the covering layer as a whole. With such arrangement, the structural reliability of the cable assembly of the present disclosure is relatively high. A cable connector having the cable assembly and a method of manufacturing the cable assembly are also disclosed.