Flat Cable Reinforcement Plate Segmentation for Terminal Strength
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Solution Overview
Problem
Existing flat cables face challenges in achieving sufficient terminal strength and preventing gold plating liquid ingress at the interface between conductors and insulating layers, while also ensuring easy adjustment of terminal thickness for connector insertion, especially with high-frequency and high-speed signal transmission requirements.
Innovation Solution
A flat cable configuration featuring parallel conductors with insulating layers on both surfaces, including a reinforcement plate directly formed on the conductors and between the conductors and insulating layers, allowing for adjustable terminal thickness and secure connector integration, along with a method involving specific attachment and division steps to ensure reinforcement plate placement and gold plating prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement plate is provided to have predetermined strength, then terminal strength is improved, but terminal thickness becomes difficult to adjust for connector insertion
Solution Approach 1:
The reinforcement plate is divided into multiple segments along the conductor width, with intervals between them. This segmentation allows the reinforcement plate to provide necessary strength while maintaining flexibility in thickness adjustment for different connector requirements.
Solution Approach 2:
The reinforcement plate structure is designed to be adaptable in thickness configuration, allowing adjustment between different thickness levels to match various connector insertion requirements while maintaining sufficient terminal strength.
2Reliability
If gold plating is applied to prevent whiskers, then reliability is improved, but gold plating liquid may ingress at the interface between conductors and insulating layers
Solution Approach 1:
The reinforcement plate serves as an intermediary structure between the conductor and insulating layer, creating a physical barrier that prevents gold plating liquid from reaching the interface between conductors and insulating layers during the plating process.
Solution Approach 2:
The reinforcement plate is positioned in advance to block the potential ingress path of gold plating liquid, preventing the harmful effect before it can occur during the gold plating process.
3Ease of manufacture
If the reinforcement plate is formed only on the second surfaces opposite to the exposed portion, then manufacturing is simplified, but terminal strength is insufficient
Solution Approach 1:
The reinforcement plate is segmented into multiple regions: one region formed directly on the conductor surface and another region formed between the conductor and insulating layer. This segmentation provides enhanced terminal strength while maintaining manufacturing feasibility through a systematic formation process.
Data Source
AI summary
A flat cable includes: a plurality of conductors arranged in parallel; an insulating layer formed, on first surfaces of the plurality of conductors and on second surfaces that are opposite surfaces of the first surfaces, along the plurality of conductors; an exposed portion where the first surfaces at end portions of the conductors are exposed to outside; and a reinforcement plate formed on the second surfaces opposite to the exposed portion. On the second surfaces opposite to the exposed portion, the reinforcement plate is directly formed on the conductors, and on the second surfaces opposite to the first surfaces that are in continuous with the exposed portion, the reinforcement plate is formed between the conductors and the insulating layer on the second surfaces.