Flexible Flat Cable Hot Pressing With Synchronous Multi-Unit Curing
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Solution Overview
Problem
The existing methods for producing flexible flat cables require long curing times for insulating glue, making it difficult to implement continuous automatic hot pressing, which leads to high manufacturing costs and large equipment sizes.
Innovation Solution
A hot pressing machine with multiple hot pressing units arranged along the feeding direction of the flexible flat cable, controlled by a central controller to enable synchronous hot pressing, allowing for continuous processing without the need for extended curing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flexible flat cable is heated and pressurized for curing insulating glue, then the conductor is fixed in place, but the curing time is long (half an hour) making continuous hot pressing difficult
Solution Approach 1:
The patent divides the hot pressing process into multiple sequential stages (preheating, hot pressing, cooling) that can be performed continuously on different cable sections. Multiple hot pressing units are arranged in series, allowing one unit to be in preheating while another is in hot pressing and another in cooling, thereby eliminating idle time and enabling continuous operation.
Solution Approach 2:
The patent implements preheating of the flexible flat cable before the actual hot pressing stage. This preliminary action prepares the cable and insulating glue for the curing process, ensuring optimal conditions are met before pressure is applied, which helps reduce the overall curing time required.
2Reliability
If the flexible flat cable stands for long time for curing, then the insulating glue is properly cured, but the travel distance of automatic production line increases
Solution Approach 1:
The production line is segmented into multiple compact hot pressing units arranged in series, each performing a specific stage of the curing process. This segmentation allows the cable to move through a shorter, more compact line while still receiving the full curing treatment across multiple stages, reducing the overall travel distance compared to a single long curing zone.
Solution Approach 2:
The patent ensures continuous useful action by overlapping the process stages across multiple units. While one unit completes hot pressing, another is already in the cooling stage, and a third is preparing for the next cable. This continuity eliminates idle time and reduces the total line length needed to achieve the same production throughput.
3Productivity
If the hot pressing machine is designed to accommodate long travel distance, then continuous hot pressing is possible, but the equipment size becomes large
Solution Approach 1:
The hot pressing machine is divided into multiple compact, modular units that can be arranged in a compact footprint. Each unit handles a specific stage of the process, allowing the overall system to achieve continuous hot pressing capability without requiring a single large, space-consuming structure. The modular design optimizes space utilization.
Solution Approach 2:
The patent arranges multiple hot pressing units in a multi-dimensional configuration rather than a simple linear extension. By stacking or arranging units in three-dimensional space, the system achieves the necessary process length for continuous operation while minimizing the floor area occupied by the equipment.
4Area of stationary object
If manual hot pressing is used to avoid large equipment size, then floor area is reduced, but automation is lost
Solution Approach 1:
The automated system is segmented into multiple compact units, each equipped with automated control systems. This segmentation allows the automation function to be distributed across smaller modules, maintaining high automation levels while keeping each unit's footprint small and the overall equipment area reduced compared to a single large automated system.
Solution Approach 2:
Each hot pressing unit is designed as a multi-functional module that can independently perform preheating, hot pressing, and cooling operations. This universality allows the automated system to achieve complex processing capabilities through multiple simple, compact units rather than requiring a single large, specialized machine, thereby reducing floor area while maintaining automation.
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 solution enables continuous automatic hot pressing of flexible flat cables, reducing manufacturing costs and equipment size while maintaining the quality of the hot pressing process.
Implementation Method 1
the flexible flat cable needs to be heated and pressurized (hereinafter referred to as 'hot pressing')
Implementation Method 2
the flexible flat cable needs to be heated and pressurized
Data Source
AI summary
A hot pressing machine for continuously hot pressing a flexible flat cable includes a plurality of hot pressing units arranged at intervals along a feeding direction of the flexible flat cable. A central controller of the machine is operably connected to the plurality of hot pressing units and is configured to control the plurality of hot pressing units to synchronously hot press the flexible flat cable located in the plurality of hot pressing units.