Flat Cable Connector Assembly With Embedded Injection Molding
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Solution Overview
Problem
Existing wire harnesses for Type C connectors involve complex welding processes due to multiple circular conductors needing individual clamping and fixing, leading to inefficiencies and high costs, and the conductors' disorderly bundling results in large volume and identification difficulties.
Innovation Solution
A connector assembly with a flat cable and insulator integrated through embedded injection molding, where core wires are exposed for direct welding to a circuit board, simplifying the process and enabling automatic production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular conductors are used in wire harnesses, then electrical connection is achieved, but the welding process becomes complex and time-consuming
Solution Approach 1:
The patent segments the conductor structure into a flat cable with multiple core wires, each with exposed ends, eliminating the need for complex peeling and preparation of circular conductors. This segmentation allows for simpler welding processes and higher production efficiency.
Solution Approach 2:
The core wire ends are pre-exposed from the insulation layer during cable manufacturing, so that no additional peeling or preparation is needed during the welding process. This preliminary action significantly reduces the welding process complexity and time.
2Volume of moving object
If multiple circular conductors are bound together, then a complete wire harness is formed, but the volume increases and identification becomes difficult
Solution Approach 1:
The patent transitions from circular conductors bound in a disordered three-dimensional arrangement to flat core wires arranged in an ordered planar configuration. This dimensional change reduces volume and enables easy identification through systematic positioning.
3Ease of manufacture
If circular conductors with multiple layers are used, then electrical insulation and shielding are provided, but the preparation process becomes complex
Solution Approach 1:
The core wire ends are pre-exposed from the insulation layer during cable manufacturing, so that no additional peeling or preparation is needed during the welding process. This preliminary action significantly reduces the welding process complexity and time.
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 reduces manufacturing complexity, improves production efficiency, and lowers costs while ensuring compact size and stable signal transmission.
Implementation Method 1
The insulator is injection-molded onto the circuit board, the rear end of the plurality of terminals, and the front end of the row of core wires through an embedded injection molding process, such that the insulator, the circuit board, the plurality of terminals, and the row of core wires form an integral part.
Data Source
AI summary
A connector assembly includes a circuit board, a connector, a flat cable, and an insulator. The connector has a housing and a plurality of terminals disposed in the housing. The flat cable has a row of core wires and an inner insulation layer wrapping the row of core wires. A rear end of the plurality of terminals protrude from the housing and are electrically connected to the circuit board. A front end of the row of core wires are exposed from the inner insulation layer and are welded to the circuit board. The insulator is injection-molded onto the circuit board, the rear end of the plurality of terminals, and the front end of the row of core wires through an embedded injection molding process, such that the insulator, the circuit board, the plurality of terminals, and the row of core wires form an integral part.