Flat Cable Connector Assembly with Split Signal Wires
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Solution Overview
Problem
Existing cable connector assemblies are bulky, occupying excessive space in compact communication devices due to their thick holding portions, which hinders miniaturization efforts.
Innovation Solution
A cable connector assembly design featuring a flat cable with a core wire and an insulative layer, enclosed by a shielding shell and an inner mold, where the core wire is directly covered by an outer boot, and the signal detection wire is split into multiple thinner wires to reduce thickness, along with a crimping collar and conductive pads for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional cable structure with insulative layer around core wire is used, then electrical insulation is ensured, but cable thickness increases occupying excessive space
Solution Approach 1:
The patent extracts the insulative layer from around the core wire, eliminating unnecessary insulation material. The core wire is directly exposed without surrounding insulative coating, reducing cable thickness while maintaining electrical insulation through alternative design arrangements.
Solution Approach 2:
The patent segments the cable structure into distinct functional zones: core wire region, signal detection wire region, and outer boot region. This segmentation allows optimized thickness distribution where insulation is provided only where electrically necessary rather than uniformly around all wires.
2Strength
If holding portion is made thicker to ensure structural integrity, then connection reliability is improved, but space occupation increases hindering miniaturization
Solution Approach 1:
The patent applies local quality by providing structural reinforcement only in specific critical areas of the holding portion rather than uniformly thickening the entire structure. The inner mold and outer boot are strategically positioned to provide localized strength where connection integrity is most needed.
Solution Approach 2:
The patent uses composite material structure combining inner mold material and outer boot material to achieve high structural integrity with reduced overall volume. The combination of these materials provides both strength and miniaturization benefits.
Data Source
AI summary
A cable connector assembly includes: a mating portion; a flat cable electrically connecting with the mating portion, the flat cable having plural wires and an outer boot enclosed the wires, the wires including a first wire and a second wire; an inner mold enclosing a part of the mating portion and a part of the flat cable; and a shielding shell enclosed the inner mold, wherein the first wire is a core wire directly enclosed by the outer boot and the second wire comprises a core wire and an insulative layer enclosing the associated core wire.