Flexible Flat Cable Assembly with Positioning Slot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The connection strength between a flexible flat cable and a circuit board is weak, leading to potential fracturing and separation when subjected to external forces, due to the conventional welding method used for fixing core wires to conductive contacts.
Innovation Solution
The design includes a circuit board with a positioning slot and opening that allows the flexible flat cable to pass through and be securely positioned, enhancing connection strength by using a connection module and stop arms to prevent separation, and an assembling method that involves fixing the connection unit, bending the cable main body to fit through the opening, and positioning it in the slot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flexible flat cable is fixed to the circuit board merely by welding core wires to conductive contacts, then the assembly process is simple, but the connection strength is weak and the cable is vulnerable to separation under external force
Solution Approach 1:
The fixing mechanism is segmented into multiple independent components: the positioning slot in the circuit board, the clamp structure with first and second clamping portions, and the cable main body. This segmentation allows each component to perform its specific function while collectively providing strong mechanical fixation without complicating the overall assembly process.
Solution Approach 2:
The cable main body is nested within the positioning slot of the circuit board, and the clamp structure is nested around the cable main body. This nested configuration allows the components to fit together compactly, providing strong mechanical fixation while maintaining assembly simplicity and reducing the need for additional external fastening components.
2Strength
If a positioning slot and opening structure are added to enhance connection strength, then the cable is protected against separation, but the device complexity increases
Solution Approach 1:
The positioning slot serves multiple functions: it guides the cable main body during assembly, provides mechanical retention for the cable, and integrates with the clamp structure to enhance fixation. The opening in the circuit board simultaneously serves as an access path for the cable and as part of the positioning mechanism. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The positioning slot and clamp structure are merged into a single integrated fixing mechanism within the circuit board. The first clamping portion is formed by the positioning slot itself, while the second clamping portion is formed by the clamp structure. This merging eliminates the need for separate positioning and clamping components, reducing overall structural complexity while maintaining enhanced connection strength.
3Reliability
If the cable main body passes through the opening and is positioned in the positioning slot, then the connection reliability is improved, but the assembly process becomes more complex
Solution Approach 1:
The positioning slot is pre-formed in the circuit board with precise dimensions and geometry that guide the cable main body into the correct position during assembly. The opening is also pre-configured to align with the positioning slot. This preliminary preparation ensures that when the cable is inserted, it automatically assumes the correct position and orientation, improving reliability while minimizing the complexity of the assembly process.
Solution Approach 2:
The positioning slot and opening are designed with specific local geometric features (elongated shape, specific dimensions, alignment) that provide enhanced guidance and retention for the cable main body at critical locations. This localized quality enhancement ensures reliable positioning and fixation without requiring complex assembly procedures throughout the entire structure.
Data Source
AI summary
An assembly includes a circuit board and a flexible flat cable. The circuit board includes a board body having top, bottom and side faces, and a connection module. The board body is formed with a positioning slot that is formed through the top and bottom faces and that has a first length, and an opening that extends from the side face and that is in spatial communication with the positioning slot. The opening is formed through the top and bottom faces and has a second length shorter than the first length. The flexible flat cable includes a connection unit and a cable main body that has a width greater than the second length. The cable main body is able to pass through the opening, and extends through and is positioned in the positioning slot.