Flat Cable Connector Bonding Structure for Position Stability
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Solution Overview
Problem
Existing cable assemblies face challenges in stabilizing the position of flat cables relative to connectors, particularly in rotary connector devices, leading to potential movement and disconnection issues.
Innovation Solution
A cable assembly design incorporating a connector housing with thermoplastic resin bonding members that secure the flat cable to the connector, using protrusions and a heating process to melt and solidify thermoplastic material for fixation, ensuring electrical connections remain stable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a projection of the connector is inserted into a support hole of the flat cable to stabilize position, then the position stability is improved, but the manufacturing complexity increases due to additional alignment requirements
Solution Approach 1:
The patent changes the physical state of the thermoplastic resin from solid to molten and back to solid through heating and cooling processes. This parameter change allows the resin to flow into positioning structures during manufacturing, then solidify to provide stable fixation, resolving the contradiction between position stability and alignment complexity
Solution Approach 2:
The patent utilizes phase transition of thermoplastic resin between solid and molten states. During assembly, the resin is heated to molten state for easy injection into positioning structures, then cooled to solid state for stable fixation. This phase transition simplifies the alignment process while ensuring position stability
2Stability of the object's composition
If thermoplastic resin is used to bond the flat cable to the connector, then the position stability is improved, but the manufacturing process complexity increases due to heating and cooling steps
Solution Approach 1:
The patent merges the bonding function and positioning function into a single integrated process. The thermoplastic resin is injected into positioning structures that are already formed in the connector housing, combining the bonding and positioning steps into one operation rather than separate processes
Solution Approach 2:
The thermoplastic resin performs multiple functions automatically: it bonds the cable to the connector, fills positioning structures for alignment, and provides insulation. The resin's own properties (viscosity changes with temperature, adhesion to surfaces) are utilized to achieve these functions without additional mechanisms
3Strength
If the first bonding member has a larger first projected area inside the insulation contour, then the bonding strength is improved, but the material consumption increases
Solution Approach 1:
The patent applies local quality by concentrating the thermoplastic resin in specific high-strength areas (first projected area inside insulation contour) rather than uniformly distributing it. The resin is strategically placed where bonding strength is most needed, providing strong bonding while minimizing overall material consumption
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 solution effectively stabilizes the flat cable within the connector, preventing movement and ensuring reliable electrical connections, even under external forces.
Implementation Method 1
melting the thermoplastic material by abutting the heating body against the first protrusion
Implementation Method 2
solidifying the molten thermoplastic material to fix the flat cable to the mounting surface
Data Source
AI summary
A cable assembly includes a first bonding member formed of a thermoplastic resin and configured to couple an insulation and a connector housing to suppress movement of the flat cable relative to the connector. The connector housing includes a mounting surface on which the flat cable is mounted. The first bonding member includes a first portion provided inside the contour of the insulation when viewed from the first direction substantially perpendicular to the mounting surface, and a second portion extending from the first portion and provided outside the contour when viewed from the first direction. The first portion has a first projected area defined inside the contour when viewed from the first direction. The second portion has a second projected area defined outside the contour when viewed from the first direction. The first projected area is larger than the second projected area.