Flat Cable Connection Structure with Integrated Slitting Holder
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Solution Overview
Problem
The existing flat-cable connection structures require expensive dedicated processing apparatuses to form slits, which are time-consuming and prone to loosening, making assembly difficult and costly.
Innovation Solution
A connection structure that includes a flat cable with conductors and a cover, a housing with a flat cable insertion chamber and cutting blade penetration holes, and a jig with cutting blades to form slits in the cover between conductors, allowing for slit formation without expensive equipment and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slits are formed in the flat cable using a dedicated processing apparatus, then the pitch difference between conductors and terminals can be absorbed, but the manufacturing cost increases and the process becomes time-consuming
Solution Approach 1:
The patent combines the slitting operation with the existing flat cable insertion process by integrating a cutting blade into the holder that already positions the flat cable. This merges two separate operations (slitting and insertion) into one, eliminating the need for a dedicated slitting apparatus and reducing manufacturing cost while maintaining the pitch difference absorption function.
Solution Approach 2:
The holder is designed to serve multiple functions: it positions the flat cable for insertion and simultaneously provides a cutting blade to form slits in the cable. This multi-functional design eliminates the need for separate dedicated slitting equipment, reducing manufacturing complexity while achieving the required pitch accommodation.
2Reliability
If slits are formed in the flat cable before assembly, then electrical connection can be achieved, but the flat cable tends to loosen at the slit areas making assembly difficult
Solution Approach 1:
The cutting blade is positioned to form slits in the flat cable at the exact moment of insertion into the holder, rather than pre-forming slits before assembly. This preliminary action during the assembly process itself prevents cable loosening while still achieving the necessary electrical connection through the slits.
Solution Approach 2:
The slitting action is merged with the insertion action, so that the cable is slit and inserted in a single coordinated motion. This prevents the cable from loosening at slit areas that would occur if slits were formed separately before assembly, while still achieving reliable electrical connection.
3Manufacturing precision
If a dedicated slitting apparatus is used to form slits in the flat cable, then precise slit formation is achieved, but the device complexity and cost increase
Solution Approach 1:
The cutting blade is integrated into the existing holder structure that is already part of the assembly device. This merges the slitting function into the existing apparatus, eliminating the need for a separate dedicated slitting machine and reducing overall device complexity while maintaining precise slit formation through the controlled cutting action.
Solution Approach 2:
The holder is designed to perform multiple functions including positioning the flat cable and providing a cutting blade for slit formation. This multi-functional design eliminates the need for separate dedicated slitting equipment, reducing device complexity while achieving precise slit formation necessary for electrical connection.
Data Source
AI summary
A holder has a flat cable insertion chamber for a flat cable to be inserted and a cutting blade penetration hole penetrating the flat cable insertion chamber. A jig has a cutting blade penetrating the cutting blade penetration hole of the holder with the flat cable inserted into the flat cable insertion chamber and forming a slit in a cover between a plurality of conductors of the flat cable.