Composite Substrate Layout Using Flat Cables for Compact Interconnection
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Solution Overview
Problem
The use of large-diameter cables in electrical devices makes it difficult to achieve space savings, shorten cable line lengths, and maintain cable integrity due to the need for a significant cable processing area and poor maintainability.
Innovation Solution
Interconnecting three or more substrates using flat cables, where each substrate has specific connectors aligned in a particular direction, allowing flat cables to be compactly arranged and superposed, thereby reducing the cross-sectional area required for installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If large-diameter cables are used to connect substrates, then cable processing area is increased, but space saving becomes difficult and line lengths cannot be shortened
Solution Approach 1:
The patent divides the cable connection system into multiple flat cables, each connecting specific connector pairs between substrates. Instead of using a single large-diameter cable, the connection is segmented into multiple smaller flat cables that can be individually routed and managed, reducing the overall space required while maintaining all necessary connections
Solution Approach 2:
The patent transitions from using large-diameter cables (one-dimensional thickness) to flat cables (two-dimensional thin profile). This dimensional change allows the cables to be stacked or arranged in layers between substrates, significantly reducing the vertical space required for cable processing areas and enabling more compact substrate arrangements
2Ease of operation
If large-diameter cables are used for substrate connection, then cable flexibility is reduced, but maintainability becomes poor
Solution Approach 1:
By segmenting the connection into multiple flat cables, each cable becomes more flexible and easier to handle during installation and maintenance. Individual flat cables can be easily disconnected, replaced, or reconfigured without affecting the entire connection system, significantly improving maintainability compared to a single large-diameter cable
Solution Approach 2:
The patent employs flat cables with flexible thin-film structures that maintain high flexibility while enabling easy routing and connection. These thin-film flexible cables can be easily bent, routed through tight spaces, and manipulated during maintenance operations, overcoming the rigidity issues associated with large-diameter cables
3Volume of moving object
If flat cables are used to connect substrates, then space saving is achieved, but connector alignment requirements increase
Solution Approach 1:
The patent designs connectors with universal alignment features that work across multiple flat cable connections. Standardized connector geometries and positioning mechanisms are used throughout the system, allowing for consistent alignment procedures and reducing the precision burden on individual connection points while maintaining compact overall dimensions
Solution Approach 2:
The patent employs nested or layered arrangements of flat cables between substrates, where cables are organized in hierarchical layers with defined routing paths. This nesting structure provides natural alignment guidance and reduces the need for high-precision positioning by constraining cable positions within defined channels or slots
Data Source
AI summary
The purpose of the present invention is to compactly interconnect at least three substrates with flat cables. A composite substrate according to the present invention includes: a first substrate including a first connector and a second connector in which the width directions thereof are parallel to a first direction; a second substrate including a third connector and a fourth connector in which the width directions thereof are parallel to the first direction; a third substrate including a fifth connector and a sixth connector in which the width directions thereof are parallel to the first direction; a first flat cable connecting the first connector and the third connector; a second flat cable connecting the second connector and the fifth connector; and a third flat cable connecting the fourth connector and the sixth connector.