Flexible Flat Cable Lamination for Fold-Stable Impedance
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Solution Overview
Problem
Traditional flexible flat cables (FFCs) experience uneven impedance distribution and signal degradation when folded due to insufficient adhesion and lack of flexibility in the dielectric material layer, leading to increased return loss and insertion loss.
Innovation Solution
A flexible flat cable design featuring a single low-dielectric mixed material layer composed of Maleic Anhydride grafted Polyolefin Elastomer (MAH-g-POE) and Polyolefin Elastomer (POE) with conductors embedded within, directly laminated conductive material layers, and insulating protective layers, which enhances adhesion and flexibility, maintaining uniform impedance and transmission characteristics even when folded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin adhesive layer is used to bond conductive material layers to the dielectric material layer, then the cable structure is simpler and easier to manufacture, but the adhesion is insufficient causing delamination at folded areas
Solution Approach 1:
The patent removes the separate adhesive layer entirely and replaces it with a dielectric material layer that has inherent adhesive properties. This extraction of the adhesive function from a separate layer and integration into the dielectric material layer itself resolves the contradiction by providing sufficient adhesion without requiring a thin adhesive layer, thus maintaining ease of manufacture while improving reliability.
Solution Approach 2:
The patent combines the adhesive function with the dielectric material layer function into a single integrated layer. By merging these two functions that were previously separated (adhesive layer + dielectric material layer), the invention achieves both sufficient adhesion for folded areas and structural simplicity, resolving the contradiction between ease of manufacture and adhesion reliability.
2Strength
If the dielectric material layer lacks flexibility to maintain structural integrity, then the cable has better mechanical strength, but it results in cracks or fissures at folded areas
Solution Approach 1:
The patent employs composite material construction where the dielectric material layer is made from a mixture of polyolefin elastomer (POE) and maleic anhydride grafted polyolefin elastomer (MAH-g-POE). This composite material provides both the mechanical strength needed for structural integrity and the flexibility required to prevent cracks at folded areas, thus resolving the contradiction between strength and flexibility.
Solution Approach 2:
The patent changes the material parameters of the dielectric layer by selecting specific material compositions (POE and MAH-g-POE mixture) with appropriate elastomeric properties. This parameter change enables the material to simultaneously achieve sufficient mechanical strength and flexibility, allowing the cable to maintain structural integrity while adapting to folding without cracking.
3Adaptability or versatility
If the spacing and dielectric constant between conductive material layers are not maintained uniformly, then the cable can be more flexible, but it causes uneven impedance distribution and signal degradation
Solution Approach 1:
The patent applies preliminary action by pre-establishing the adhesive properties and dimensional stability in the dielectric material layer before the folding occurs. The inherent adhesion and elastomeric characteristics are built into the material structure in advance, ensuring that spacing and dielectric constant remain uniform even when folding occurs, thus maintaining impedance uniformity while allowing flexibility.
Solution Approach 2:
The patent changes the physical parameters of the dielectric material layer by using elastomeric materials with specific mechanical and electrical properties. These parameter changes enable the material to maintain uniform spacing and dielectric constant during folding, resolving the contradiction between flexibility and impedance uniformity by allowing the material to deform uniformly without creating gaps or voids.
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 cable maintains consistent insertion loss and characteristic impedance before and after folding, ensuring reliable signal transmission by preventing impedance changes and cracking at folded areas.
Implementation Method 1
The single low-dielectric mixed material layer includes a mixture of Maleic Anhydride grafted Polyolefin Elastomer (MAH-g-POE) and Polyolefin Elastomer (POE)... The adhesion between the single low-dielectric mixed material layer and each conductive material layer is greater than or equal to 20 N/mm
Implementation Method 2
The dielectric constant and thickness of a dielectric material layer located between two conductive material layers... will affect the characteristic impedance of the strip line... the dielectric material layer between the two conductive material layers must have sufficient adhesion to maintain consistent spacing and dielectric constant
Implementation Method 3
The single low-dielectric mixed material layer includes a mixture of Maleic Anhydride grafted Polyolefin Elastomer (MAH-g-POE) and Polyolefin Elastomer (POE)... the dielectric material layer itself may lack sufficient flexibility, resulting in cracks or fissures at the folded area
Data Source
AI summary
The present invention discloses a flexible flat cable, including a single low-dielectric mixed material layer, a plurality of conductor, two conductive material layers and two insulating protective layers. These conductors are located inside the single low-dielectric mixed material layer and are spaced apart. The two conductive material layers are laminated individually to the upper and lower surfaces of the single low-dielectric mixed material layer. The two insulating protective layers are laminated individually to the two conductive material layers.