Flat Cable Insert Structure for Short-Circuit Prevention
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Solution Overview
Problem
Conventional flat cables can experience short circuits when incorrectly inserted into connectors, leading to potential damage of internal components due to overcurrent.
Innovation Solution
The flat cable design incorporates protruding portions at the cable insert part, creating a predetermined gap between the conductor and the connector lead, preventing direct contact and ensuring safe insertion by maintaining a stable gap even when the cable is inserted improperly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flat cable is inserted into the connector without protruding portions, then the insertion process is simple, but a short circuit may occur when the cable is incorrectly inserted
Solution Approach 1:
The protruding portions are formed on the cable insert part before insertion into the connector. These protruding portions advance ahead of the conductors and make contact with the connector housing first, preventing the conductors from contacting the connector leads even if insertion is incorrect. This preliminary action ensures short-circuit prevention is built into the insertion process itself.
2Reliability
If protruding portions are added to the cable insert part, then short-circuit prevention is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The cable insert part is segmented into distinct functional zones: the protruding portions that prevent short-circuits, the conductors that carry signals, and the insulation layers that isolate them. This segmentation allows each component to be optimized independently while maintaining overall manufacturing efficiency through standardized processes.
Solution Approach 2:
The protruding portions are integrated directly into the cable insert part structure during the insulation coating process, rather than being added as separate components. This merging of functions (structural support and short-circuit prevention) into a single integrated component simplifies the overall manufacturing process despite the added functionality.
3Reliability
If the conductor extends to the end of the cable insert part, then the electrical connection is maximized, but direct contact with connector lead causes short circuit during incorrect insertion
Solution Approach 1:
The protruding portions act as an intermediary element between the cable insert part and the connector leads. They extend beyond the conductor ends and make contact with the connector housing first, serving as a protective mediator that prevents direct contact between conductors and leads during incorrect insertion, while allowing normal connection when inserted correctly.
Data Source
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AI summary
Disclosed is a flat cable with an improved function of preventing a short phenomenon that may occur when the flat cable is incorrectly inserted into a connector. The flat cable according to an embodiment of the present disclosure is a flat cable extending straight in a direction and having a front end that is inserted and connected to an external connector, and includes a plurality of conductors extending straight along a lengthwise direction of the flat cable, spaced apart a predetermined distance in a widthwise direction of the flat cable, and a cable body made of an insulating material, and extending straight along the lengthwise direction of the flat cable, wherein the conductors are mounted on at least one surface.