Connector-Attached Cable Layout for Single-Step Laser Processing
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Solution Overview
Problem
Existing connector-attached cables require multiple processing steps for connecting electronic wires to a circuit board, particularly for coaxial wires, which complicates the preliminary processing and increases the time required for laser irradiation to expose conductors and insulating layers.
Innovation Solution
The connector-attached cable is designed with electronic wires arranged such that the overlapping width between pairs connected to different surfaces is minimized, satisfying the relationship S≥0.35d, allowing for reduced overlap and simplified laser processing by irradiating all wires in one operation, thus reducing the number of processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electronic wires are arranged with larger overlap between pairs connected to different surfaces, then the connection structure is more compact, but the laser processing time increases and multiple processing steps are required
Solution Approach 1:
The patent applies dimensional arrangement by connecting some electronic wires to the first surface and other wires to the second surface of the circuit board, creating a three-dimensional wire routing configuration. This spatial distribution reduces the overlapping width between wire pairs in projection view while maintaining compact overall structure, enabling single-step laser processing.
2Volume of moving object
If electronic wires are arranged with larger overlap between pairs connected to different surfaces, then the connection structure is more compact, but the number of processing steps increases
Solution Approach 1:
By utilizing both surfaces of the circuit board for wire connections, the patent reduces the projection overlap between wire pairs. This dimensional arrangement allows all wires to be processed in a single laser processing step, eliminating the need for multiple processing steps that would be required with traditional planar arrangements.
3Productivity
If the overlapping width between electronic wire pairs is reduced, then laser processing is simplified to one operation, but the connection structure becomes less compact
Solution Approach 1:
The patent resolves this contradiction by distributing wire pairs across two surfaces of the circuit board. This three-dimensional configuration reduces the projection overlap width to enable single-step laser processing while maintaining compact overall structure through vertical arrangement, rather than increasing horizontal spacing.
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 configuration simplifies the connection process by reducing the overlap between electronic wires, enabling efficient preliminary processing with fewer laser irradiation steps and streamlining the connection of coaxial wires to the circuit board.
Implementation Method 1
irradiating all wires in one operation
Data Source
AI summary
A connector-attached cable includes a cable including a plurality of electronic wires; and a connector connected to the cable. The connector includes a circuit board, each of the electronic wires includes a conductor and an insulating layer covering the conductor. The plurality of electronic wires is connected to the circuit board. The plurality of conductors is connected to a first surface and a second surface of the circuit board. An overlapping width between an electronic wire pair in a first group connected to the first surface and an electronic wire pair in a second group connected to the second surface is smaller than a diameter of the electronic wire. When a distance between center lines of two of the electronic wires is set as S, and a diameter of the insulating layer of the electronic wire is set as d, a relationship of S≥0.35d is satisfied.