High-Speed Flat Cable Bending Memory via Composite Layers
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Solution Overview
Problem
Existing high-speed flat cables have poor bending/folding memory, causing them to rebound easily and making them unsuitable for compact electronic equipment, as they are thick and difficult to install.
Innovation Solution
A high-speed flat cable design featuring shielded signal units surrounded by two bendable composite layers, each comprising an inner insulating film, a bendable aluminum foil layer, and an outer insulating film, with an adhesive layer between the composite layers to enhance mechanical bending/folding memory, and a manufacturing method involving extrusion and lamination of core and ground wires with shielding layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional Mylar covering structure is used, then the cable has simple structure, but the bending/folding memory is poor and the cable rebounds easily
Solution Approach 1:
The patent applies composite materials by replacing traditional Mylar covering with a multi-layer composite structure consisting of inner insulating film, aluminum foil layer, and outer insulating film. This composite structure provides superior bending/folding memory and rebound resistance compared to single-material Mylar covering, directly resolving the contradiction between structural simplicity and bending memory performance.
Solution Approach 2:
The patent implements local quality by assigning different functional properties to different layers of the composite structure: the inner insulating film provides insulation and adhesion, the aluminum foil layer provides mechanical strength and bendability, and the outer insulating film provides protection. This differentiated local quality enables the cable to achieve excellent bending/folding memory while maintaining reasonable structural complexity.
2Ease of operation
If traditional flat cable structure is used, then the cable has sufficient strength, but the thickness is more than 1 mm making it difficult to install in compact equipment
Solution Approach 1:
The patent employs flexible shells and thin films by using thin insulating film layers and aluminum foil layers that provide sufficient mechanical strength and protection while maintaining minimal thickness. This enables the cable to be less than 1 mm thick, significantly improving ease of installation in compact electronic equipment compared to traditional thicker flat cables.
3Volume of moving object
If the cable is made thinner for compact installation, then the installation ease improves, but the mechanical strength and shielding performance may deteriorate
Solution Approach 1:
The patent uses composite materials with the aluminum foil layer providing mechanical strength and electromagnetic shielding, while the thin insulating film layers provide structural integrity. This composite approach enables the cable to maintain sufficient mechanical strength and shielding performance despite being thinner than 1 mm, resolving the contradiction between thickness reduction and strength maintenance.
Solution Approach 2:
The patent applies local quality by concentrating mechanical strength and shielding functions in the aluminum foil layer, while the insulating film layers provide structural support. This functional differentiation allows the cable to achieve reduced overall thickness without compromising mechanical strength, as each layer contributes its specific property to the overall performance.
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 a folded position with minimal relaxation, allowing for easier installation and improved assembly efficiency, with a thickness reduced to less than 1 mm, enhancing its mechanical bending/folding performance.
Implementation Method 1
an adhesive layer, wherein the adhesive layer is located between the two bendable composite layers for the bendable composite layers at the periphery of the signal units to be adhered to each other
Implementation Method 2
the outer insulating film layer and the inner insulating film layer each have a width slightly greater than that of the bendable aluminum foil layer so as to block the bendable aluminum foil layer from being in contact with the outside
Implementation Method 3
a high-speed flat cable having a better bending/folding memory by retaining a folded position for a particular period of time without rebounding
Data Source
AI summary
A high-speed flat cable includes a plurality of shielded signal units, one or more bendable composite layers, and an adhesive layer. The shielded signal units are substantially coplanar, spaced apart from each other or adjoining each other. The one or more bendable composite layers includes an inner insulating film layer, a bendable aluminum foil layer, and an outer insulating film layer. The one or more bendable composite layers composed of the inner insulating film layer, the bendable aluminum foil layer, and the outer insulating film layer increase its mechanical bending/folding property to improve the bending/folding memory. The one or more bendable composite layers allows the flat cable to be bent with ease without rebounding, thereby enhancing production efficiency.